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

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SERVICE STATION MANUAL
981103
1200 SPORT 4V ABS

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Summary of Contents for MOTO GUZZI 1200 SPORT 4V ABS

  • Page 1 SERVICE STATION MANUAL 981103 1200 SPORT 4V ABS...

  • 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 2008- Moto Guzzi. All rights reserved. Reproduction of this publication in whole or in part is prohibited. Moto Guzzi - After sales service.
  • Page 3 In order to optimise customer satisfaction when using our vehicles, Moto Guzzi s.p.a. commits itself to continually improve its products and the relative documentation. The main technical modifications and changes in repair procedures are communicated to all Moto Guzzi Sales Outlets and its International Subsidiaries.

  • Page 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

    1200 SPORT 4V ABS Characteristics Rules Safety rules Carbon monoxide If you need to keep the engine running while working on the vehicle, please ensure that you do so in an open or very well ventilated area. Never run the engine in an enclosed area. If you do work in an enclosed area, make sure to use a fume extraction system.
  • Page 8 1200 SPORT 4V ABS Characteristics Brake and clutch fluid BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAINTED SURFACES. WHEN SERVICING THE BRAKING SYSTEM OR THE CLUTCH SYSTEM, PROTECT THESE COM- PONENTS WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THESE SYSTEMS.

  • Page 9: Electric Connectors

    CAUTION BEARINGS MUST BE ABLE TO ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE: OTH- ERWISE, THEY NEED TO BE REPLACED. • Only use ORIGINAL Moto Guzzi SPARE PARTS. • Comply with lubricant and consumables use guidelines. • Lubricate parts (whenever possible) before reassembling them.

  • Page 10: 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

    1200 SPORT 4V ABS Characteristics This number consists of numbers and letters, as in the example shown below. ZGULPR010YMXXXXXX KEY: ZGU: WMI (World manufacturer identifier) code; LP: model; R01: version variation; 0: digit free Y year of manufacture M: production plant (M= Mandello del Lario);...
  • Page 12 1200 SPORT 4V ABS Characteristics Specification Desc./Quantity Compression ratio 11 : 1 Electric starter Engine idle speed 1100 ± 100 rpm Clutch hydraulically controlled single-plate dry clutch with incorpora- ted flexible coupling Lubrication system Pressure-fed, controlled by valves and trochoidal pump...
  • Page 13 1200 SPORT 4V ABS Characteristics Specification Desc./Quantity High-beam light 12 V - 65 W H9 Turn indicators 12V - 10 W (orange bulb) Rear daylight running light/stop light Dashboard lighting License plate light 12V - 5 W Turn indicator warning light...

  • Page 14: Wheels And Tyres

    1200 SPORT 4V ABS Characteristics Wheels and tyres WHEELS AND TYRES Specification Desc./Quantity Type hollow 3-spoke rim in chilled cast aluminium alloy Front wheel rim 3.50" x 17" Rear wheel rim 5.50" x 17" Tyres METZELER Roadtec Z6 METZELER Sportec M5...
  • Page 15 1200 SPORT 4V ABS Characteristics OIL SUMP Name Torque in Nm Oil pipe on sump reduction (1) 20 Nm (14.75 lb ft) Oil pipe on sump 20 Nm (14.75 lb ft) Oil sump lower screw - TCEI M6x30 (4) 10 Nm (7.38 lb ft) Oil sump screw - TCEI M6x55 (14) 10 Nm (7.38 lb ft)

  • Page 16: Side Stand

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

  • Page 17: Rear Suspension

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

  • Page 18: Fuel Tank

    1200 SPORT 4V ABS Characteristics ELECTRICAL SYSTEM Name Torque in Nm Horn retainer 15 Nm Speed sensor to front fork retainer 12 Nm INSTRUMENT PANEL AND LIGHTS Name Torque in Nm Instrument panel support to light support retainer 10 Nm...

  • Page 19: Piston Rings

    1200 SPORT 4V ABS Characteristics Check clearance between cylinders and pistons on the selected diameter; if it exceeds the value speci- fied, it is necessary to replace cylinders and pistons. The pistons of an engine must be balanced; a weight difference of up to 1.5 g (0.0033 lb) is allowed.
  • Page 20 1200 SPORT 4V ABS Characteristics CLEARANCE BETWEEN PISTON RINGS AND SEATS ON PISTON Specification Desc./Quantity Top ring 0.030 - 0.065 mm (0.00118 - 0.00256 in) Middle ring 0.020 - 0.055 mm (0.00079 - 0.00216 in) Oil scraper ring 0.010 - 0.045 mm (0.00039 - 0.00177 in) Gap between the end of the piston rings inserted in the cylinder: •...
  • Page 21 1200 SPORT 4V ABS Characteristics 020676Y Dial gauge support for piston position checking • Reset the micrometer on the cylinder rim. • Move the tool so that the micrometer feeler reaches the top point of the piston crown. • Take note of the measurement and, according to the values found, consult the chart at the bottom of the page to decide the thickness of the gasket to be fitted between cylinder and head.
  • Page 22 1200 SPORT 4V ABS Characteristics ECOMMENDED PRODUCTS Product Description Specifications ENI i-RIDE PG 10W-60 Lubricant formulated with advanced syn- JASO MA, MA2 - API SG thetic technology and high performance additives to cater specifically for 4-stroke engines with high specific power outputs.

  • Page 23: Index Of Topics

    INDEX OF TOPICS S-TOOLS PECIAL TOOLS...

  • Page 24: Special Tools

    1200 SPORT 4V ABS Special tools SPECIAL TOOLS Stores code Description 020677Y Generator belt tensioner, lever for belt tensioning 05.91.17.30 Front cover insertion cone 020716Y Connecting rod locking 020470Y Pin snap ring fitting tool 05.92.72.30 Timing system cover sealing ring punch 01.92.91.00...
  • Page 25 1200 SPORT 4V ABS Special tools Stores code Description 05.90.25.30 Gearbox support 19.92.96.00 Graduated dial to control ignition timing 17.94.75.60 Arrow to control ignition timing 12.91.18.01 Tool to lock the flywheel and the starting ring gear 12.91.36.00 Tool to remove the flywheel-side flange...
  • Page 26 1200 SPORT 4V ABS Special tools Stores code Description 14.92.71.00 Tool to fit the sealing ring on the flywheel- side flange 12.91.20.00 Tool to fit the flywheel-side flange togeth- er with seal ring on the crankshaft 19.92.71.00 Tool to fit the seal ring on the flywheel-...
  • Page 27 1200 SPORT 4V ABS Special tools Stores code Description 020676Y Dial gauge support for piston position checking 020678Y Tool for clutch rod checking AP8140190 Tool for steering tightening 05.90.27.30 Gearbox support 05.90.27.31 Gearbox oil seal buffer 05.90.27.32 Buffer handgrip 05.90.27.33...
  • Page 28 1200 SPORT 4V ABS Special tools Stores code Description 05.90.27.34 Wrench for pinion ring nut 05.90.27.35 Pinion oil seal buffer 05.90.27.36 Bevel gear pair support 020689Y Spark plug removal GU14912603 Hook spanner for fixing ring nut of the clutch shaft internal body...

  • Page 29: Maintenance

    INDEX OF TOPICS MAIN AINTENANCE...

  • Page 30: Scheduled Maintenance Table

    1200 SPORT 4V ABS Maintenance Scheduled maintenance table NOTE CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VE- HICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS, OFF ROAD OR FOR TRACK USE. I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE (1) Check and clean and adjust or replace, if necessary, before every journey.

  • Page 31: Spark Plug

    1200 SPORT 4V ABS Maintenance AT EACH SCHEDULED MAINTENANCE MUST BE VERIFIED WITH THE DIAGNOSTIC TOOL IF THERE ARE ERRORS AND THE IF THE PARAMETERS ARE CORRECT. Spark plug For removal: • With a flat screwdriver, remove the Mo- to Guzzi oval symbol.

  • Page 32: Transmission Fluid

    1200 SPORT 4V ABS Maintenance • Check the electrode gap with a feeler thickness gauge (5). CAUTION DO NOT ATTEMPT TO READJUST THE ELECTRODE GAP. The electrode gap should be between 0.6 - 0.7 mm (0.023 - 0.027 in). Replace the spark plug if the gap is different.

  • Page 33: Engine Oil

    1200 SPORT 4V ABS Maintenance DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO THE FLUID. WHEN USING A FUNNEL OR ANY OTHER EL- EMENT, MAKE SURE IT IS PERFECTLY CLEAN. Replacement CAUTION THE UNIT MUST BE HOT WHEN THE OIL IS CHANGED AS UNDER SUCH CONDITIONS OIL IS FLUID AND THEREFORE EASY TO DRAIN.
  • Page 34 1200 SPORT 4V ABS Maintenance • Shut off the engine. • Keep the vehicle upright with the two wheels on the ground. • Unscrew and remove the dipstick (1). • Clean the dipstick (1). • Reinsert the dipstick (1) into the open- ing but do not screw it.

  • Page 35: Engine Oil Filter

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

  • Page 37: Air Filter

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

  • Page 38: Braking System

    1200 SPORT 4V ABS Maintenance ADJUST WITH COLD ENGINE, WITH PISTON AT TOP DEAD CENTRE (TDC) IN COMPRESSION STROKE (VALVES CLOSED). • Disconnect both spark plug caps. • Unscrew and remove the four head cover fixing screws and collect the sealing O-rings.
  • Page 39 1200 SPORT 4V ABS Maintenance If the fluid does not reach at least the "MIN" reference mark: • Check brake pads and disc for wear. • If the pads and/or the disc do not need replacing, top-up the fluid. Top-up Front brake: •...
  • Page 40 CHECK BRAKING EFFICIENCY. IN CASE OF EXCESSIVE TRAVEL OF THE BRAKE LEVER OR POOR PERFORM- ANCE OF THE BRAKING SYSTEM, TAKE YOUR VEHICLE TO AN Official Moto Guzzi Dealer, AS IT MAY BE NECES- SARY TO PURGE THE AIR IN THE SYSTEM. MAIN - 40...

  • Page 41: Electrical System

    INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 42 1200 SPORT 4V ABS Electrical system Components arrangement Key: 1 Coil 2 Instrument panel 3 Fuel pump 4 Injector ELE SYS - 42...

  • Page 43: Electrical System Installation

    1200 SPORT 4V ABS Electrical system 5 Throttle valve potentiometer 6 Fall sensor 7 Rear light 8 Battery 9 Main fuses 10 Lambda probe 11 Intake air temperature sensor 12 Engine revolution sensor 13 Auxiliary fuses 14 Head temperature sensor...

  • Page 44: General Wiring Diagram

    1200 SPORT 4V ABS Electrical system General wiring diagram Key: 1. MULTIPLE CONNECTORS 2. GPS 3. CLUTCH SWITCH 4. MAINTENANCE RELAY ELE SYS - 44...
  • Page 45 1200 SPORT 4V ABS Electrical system 5. START-UP RELAY 6. LIGHT RELAY 7. RIGHT LIGHT SWITCH 8. HAZARD BUTTON 9. ABS BUTTON 10.HORN 11.LEFT LIGHT SWITCH 12.INSTRUMENT PANEL AIR TEMPERATURE THERMISTOR 13.INSTRUMENT PANEL 14.KEY SWITCH 15.IMMOBILIZER AERIAL 16.HEATED HANDGRIPS 17.HEATED HANDGRIP CONTROL 18.REAR RIGHT TURN INDICATOR...

  • Page 46: Checks And Inspections

    1200 SPORT 4V ABS Electrical system 43.FUEL LEVEL SENSOR 44.FUEL PUMP 45.INTAKE AIR TEMPERATURE THERMISTOR 46.HEAD TEMPERATURE THERMISTOR 47.AUTOMATIC AIR 48.THROTTLE VALVE POSITION SENSOR 49.RIGHT CYLINDER COIL 50.RIGHT CYLINDER SPARK PLUG 51.LEFT CYLINDER COIL 52.LEFT CYLINDER SPARK PLUG 53.RIGHT CYLINDER INJECTOR 54.LEFT CYLINDER INJECTOR...

  • Page 47: Enter New Code

    1200 SPORT 4V ABS Electrical system Dashboard Diagnosis Changing the CODE If you know the code, just enter it and then a new code that will be automatically stored in the memory. If the vehicle is new, the user code is: 00000 Resetting the CODE This function is used to set a new code when the old one is not available;...
  • Page 48 1200 SPORT 4V ABS Electrical system Coil 1 Error DC V DC ECU 22 Coil 1 Error DC Gnd ECU 23 Coil 2 Error DC V DC ECU 24 Coil 2 Error DC Gnd ECU 25 Injector 1 Error DC V DC ECU 26...
  • Page 49 Use the Ditech connector in the Axone 2000 Apri- lia-Moto Guzzi package to connect to the Axone cable. KEY CHANGE FUNCTION This function can be used: 1) if one key is lost;...

  • Page 50: Checking The Stator

    1200 SPORT 4V ABS Electrical system Checking the stator Single-phase generator with regulated voltage Maximum load 40A (550W) Charging voltage 14.2 - 14.8 V (5000 rpm) Start-up system check pick-up input about 100 A level indicators Petrol pump: Input: 3.5 A (to be measured between pins 1 and...

  • Page 51: Front Headlamp

    1200 SPORT 4V ABS Electrical system Lights list FRONT HEADLAMP Tail light: 12V - 5W Low-beam light: 12 V - 55 W H7 High-beam light: 12 V - 65 W H9 REAR LIGHT Fuses AUXILIARY FUSES A - Stop, horn, Hazard button lighting, relay coil lights (15 A).

  • Page 52: Main Fuses

    1200 SPORT 4V ABS 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. ABS FUSES 3 - ABS pump (40 A).
  • Page 53 1200 SPORT 4V ABS Electrical system 11 Not used 12 Not used 13 Not used 14 Air temperature signal 15 Not used 16 Not used 17 Stepper motor (+) 18 Stepper motor (-) 19 Stepper motor (-) 20 5V power supply (NTC sensors)
  • Page 54 1200 SPORT 4V ABS Electrical system 9 Not used 10 Not used 11 Oxygen probe negative control 12 Not used 13 Not used 14 Not used 15 Not used 16 K line (diagnosis) 17 Power supply from main relay 18 Not used...
  • Page 55 1200 SPORT 4V ABS Electrical system Pin Use 1 Earth connection 2 ABS pump supply 3 ABS pump supply 4 Earth connection 5 Front (ABS) speed sensor (supply) 6 Not used 7 Rear (ABS) speed sensor (supply) 8 Not used...

  • Page 56: Engine Rpm Sensor

    1200 SPORT 4V ABS Electrical system Battery 12 V - 18 Ampere/hour Engine rpm sensor Function It informs crankshaft position and speed to the Marelli control unit. Operation / operating principle Inductive sensor: sinusoidal-type generated volt- age; two teeth are missing on the flywheel for the reference position.

  • Page 57: Throttle Position Sensor

    1200 SPORT 4V ABS Electrical system 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 58 1200 SPORT 4V ABS Electrical system • PINS A-C: throttle closed approx. 2.5 kOhm; throttle open approx. 1.5 kOhm. • PINS A-B: approx. 1.1 kOhm Pin-out: • PIN A: ground connection • PIN B: supply voltage +5V • PIN C: potentiometer signal THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS;...

  • Page 59: Reset Procedure

    1200 SPORT 4V ABS Electrical system resistance. If resistance is over 2.5 kOhm, it means the red cable is shorted to positive and the cable harness should be restored • shorted to negative: disconnect the sensor connector and check the ground insulation of the red cable (from throttle sensor connector or control unit connector): if there is continuity to ground, restore the cable harness;...
  • Page 60 1200 SPORT 4V ABS 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)

  • Page 61: Air Temperature Sensor

    1200 SPORT 4V ABS Electrical system error is displayed at the same time, this means that the grey cable common for both sensors is shorted to positive. • If shorted to negative, check sensor correct resistance: if resistance = 0, replace the sensor;...
  • Page 62 1200 SPORT 4V ABS Electrical system Air temperature In case of failure, 25°C is set as temperature AXONE: ELECTRICAL ERRORS Air temperature sensor P0110 - Open circuit, shorted to positive / shorted to negative Error cause • If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 14 of the BROWN connector.

  • Page 63: Lambda Sensor

    1200 SPORT 4V ABS Electrical system Lambda sensor Function In charge of telling the control unit whether the mixture is lean or rich. Operation / operating principle The Marelli injection control unit reads and inter- prets a voltage generated by the difference in oxy- gen content between the exhaust fumes and the ambient.
  • Page 64 1200 SPORT 4V ABS Electrical system NAVIGATOR: STATUSES Lambda check Example value: Open loop / Closed loop Closed loop indicates that the control unit is using the lambda probe signal to keep the combustion as close as possible to the stoichiometric value.
  • Page 65 1200 SPORT 4V ABS Electrical system PIN 3 of the sensor connector PIN 3 and PIN 11 of the BLUE connector) and restore the cable harness. Injector Function To supply the correct amount of petrol at the right timing. Operation / operating principle Injector coil is excited for the petrol passage to open.
  • Page 66 1200 SPORT 4V ABS Electrical system • Shorted to positive: disconnect the injector connector, take the key to ON and check if there is voltage on the grey/red cable: if there is voltage, restore the cable harness. If there is no voltage, replace the injector.
  • Page 67 1200 SPORT 4V ABS Electrical system tween PIN 37 of the BROWN connector and the component PIN - and restore the cable harness. Coil Function It controls the ignition spark plug in order to gen- erate the fuel ignition spark.
  • Page 68 1200 SPORT 4V ABS Electrical system • If shorted to positive: excessive voltage has been detected at PIN 38 of the BROWN con- nector. • If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 38...

  • Page 69: Engine Oil Pressure Sensor

    1200 SPORT 4V ABS Electrical system continuity, restore the cable harness; if there is cable continuity, with the key set to KEY ON, check the cable ground insulation (from coil connector or control unit connector). If this is not OK, restore the cable harness.
  • Page 70 1200 SPORT 4V ABS Electrical system It this error persists, use a pressure gauge to check the pressure of the oil in the engine circuit Neutral sensor Function it tells the gear position to the control unit: in neutral or in gear.
  • Page 71 1200 SPORT 4V ABS Electrical system that the grey/black cable from PIN 1 of the sensor to PIN 23 of the BROWN connector is shorted to ground: restore the cable harness. Clutch lever sensor Function It tells the clutch lever position to the control unit.
  • Page 72 1200 SPORT 4V ABS Electrical system the sensor. If the circuit is open, it means that the yellow/purple cable from PIN 1 of the sensor to PIN 33 of the BLUE connector is shorted to ground: restore the cable harness...

  • Page 73: Bank Angle Sensor

    1200 SPORT 4V ABS Electrical system Bank angle sensor Function it tells the vehicle position to the control unit. Operation / operating principle When the sensor is inverted, the circuit is closed to ground: when the Marelli control unit detects this earthing, it disables the fuel pump circuit and the engine start-up circuit via the injection relay.
  • Page 74 1200 SPORT 4V ABS Electrical system Air temperature sensor - instrument panel Function It tells the ambient air temperature to the instru- ment panel. Operation / operating principle NTC type sensor (resistance sensor, inversely variable with temperature). Level in wiring diagram:Temperature sensors Location: •...

  • Page 75: Run/Stop Switch

    1200 SPORT 4V ABS Electrical system If a short circuit to ground is detected at PIN 9 of the instrument panel connector, the display will show a full scale air temperature indication of 60°C Check the ground insulation of the sensor connector pink cable: if there is a connection, restore the cable harness;...
  • Page 76 1200 SPORT 4V ABS Electrical system Example value:Run/Stop DIAGNOSIS • Indication on Axone always STOP: disconnect the connector and, with the switch set to RUN, check if there is continuity between the blue/green (PIN 1) cable and the grey/sky blue (PIN 4) cable (sensor side): if there is not continuity, replace the sensor;...

  • Page 77: Heated Handgrip Control

    1200 SPORT 4V ABS Electrical system 15 ANTITHEFT DEVICE LED (IF CONNECTED) 16 SELECT 3 17 SENSORS EARTH CONNECTION 18 GENERAL EARTH CONNECTION 19 GENERAL EARTH CONNECTION 20 GENERAL EARTH CONNECTION 21 + BATTERY 22 + BATTERY 23 LOW-BEAM LIGHT RELAY ACTIVATION...

  • Page 78: Index Of Topics

    INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...

  • Page 79: Vehicle Preparation

    1200 SPORT 4V ABS Engine from vehicle Vehicle preparation Before removing the engine block, proceed as follows: • From the back, secure the vehicle with belts attached to a hoist. • From the front, secure the vehicle with belts attached to the handlebar and fixed to the work bench.
  • Page 80 1200 SPORT 4V ABS Engine from vehicle • Disconnect the engine temperature sensor connector • Disconnect the revolution sensor con- nector. • Disconnect the alternator connectors. • Disconnect the gear in neutral sensor connector. ENG VE - 80...
  • Page 81 1200 SPORT 4V ABS Engine from vehicle • Unscrew and remove the stud bolt. • Disconnect the ground leads. • Disconnect the connectors of the start- er motor. • Unscrew and remove the three screws and remove the clutch control cylinder.
  • Page 82 1200 SPORT 4V ABS Engine from vehicle • Unscrew and remove the nut. • Remove the front tank protection. • Disconnect the stand sensor connec- tor and release it from the clamps. • Unscrew and remove the oil cooling ra- diator upper fixing stud bolt.
  • Page 83 1200 SPORT 4V ABS Engine from vehicle • Working from both sides, unscrew and remove the three inlet manifold screws. • Collect the gasket. • Remove both footrest holding plates. • Unscrew and remove the lower nut fix- ing the engine and collect the washer.
  • Page 84 1200 SPORT 4V ABS Engine from vehicle • Unscrew and remove the upper nut fix- ing the engine and collect the washer. • Remove the upper pin and collect the washer. • Lower the engine completely. • Lift the rear part of the vehicle.
  • Page 85 1200 SPORT 4V ABS Engine from vehicle • Working on both sides, insert the washer and screw the screw without tighten it. • Working on both sides, place the plates • Working from the left side, fit the engine lower bolt with the washer.
  • Page 86 1200 SPORT 4V ABS Engine from vehicle • Working from both sides, place the in- let manifold fitting a new gasket be- tween the manifold and head. • Fasten the inlet manifold with the three screws. • Connect the stand sensor connector and fix it to the chassis with new clamps.
  • Page 87 1200 SPORT 4V ABS Engine from vehicle • Place the front tank protection. • Screw the nut. • Fit the gearbox oil breather pipe. • Fit the clutch control cylinder. • Tighten the three screws. • Connect the starter motor connectors.
  • Page 88 1200 SPORT 4V ABS Engine from vehicle • Connect the ground leads and tighten the stud bolt. • Connect the neutral sensor connector. • Connect the alternator connectors. • Connect the revolution sensor connec- tor. ENG VE - 88...
  • Page 89 1200 SPORT 4V ABS Engine from vehicle • Connect the engine temperature sen- sor connector. • Connect and adjust the throttle grip ca- ble clearance. • Place the swingarm with cardan shaft and the rear wheel. • Working on both sides, connect the in- jector connectors.
  • Page 90 INDEX OF TOPICS NGINE...
  • Page 91 1200 SPORT 4V ABS Engine Gearbox Diagram key: 1. Ball bearing ENG - 91...
  • Page 92 1200 SPORT 4V ABS Engine 2. Circlip 3. Thickness 4. Pin 5. Complete desmodromic 6. Ball bearing 7. Spring 8. Spacer 9. Circlip 10.Fifth wheel 11.Linking pin 12.Gear 13.Circlip 14.Thrust washer 15.Roller cage 16.Gear 17.Seal ring 18.Ball bearing 19.Gear 20.Circlip 21.Clutch shaft...

  • Page 93: Removing The Gearbox

    1200 SPORT 4V ABS Engine 40.Index lever 41.Spring 42.Ball bearing 43.Gear 44.Gear 45.Roller cage 46.Thrust washer 47.Circlip 48.Gear 49.Circlip 50.Gear 51.Primary shaft 52.Transmission gear 53.Fork (5th - 1st) 54.Fork shaft 55.Fork (3rd - 4th) 56.Fork (2nd - 4th) 57.Gear 58.Gear 59.Ball bearing...
  • Page 94 1200 SPORT 4V ABS Engine • Unscrew and remove the gearbox oil filler cap. • Place a container of suitable capacity under it, unscrew and remove the cap and then bleed all gearbox oil. • Loosen and turn the oil pipe joint on the sump.

  • Page 95: Gearbox Shafts

    1200 SPORT 4V ABS Engine • Undo and remove the two screws. • Unscrew and remove the screw. • Remove the gearbox. See also Removing the starter motor Replacement Gearbox shafts ENG - 95...
  • Page 96 1200 SPORT 4V ABS Engine Disassembling the gearbox • Remove the gearbox. • Unscrew and slide off the odometer gear and collect the abutment washer that is inside the gearbox. • From the outside, slide off the thrust cylinder and collect the O-Ring and the washer.
  • Page 97 1200 SPORT 4V ABS Engine • Slide off the rod with the two bushings. • Undo and remove the five external screws. • Place the gearbox on the specific gearbox support tool and on a vice. Specific tooling 05.90.25.30 Gearbox support •...
  • Page 98 1200 SPORT 4V ABS Engine • Remove the bearings from the gearbox if necessary. • Release the spring. • Pressing the selector, slide off the whole transmission lever. • Use rubber bands to tie down the trans- mission shaft unit and extract it.
  • Page 99 1200 SPORT 4V ABS Engine • Remove the forks and collect the shaft. ENG - 99...
  • Page 100 1200 SPORT 4V ABS Engine • Replace bearings if necessary and re- move the clutch shaft. See also Removing the gearbox Removing the primary shaft • Remove the main shaft. • Operate on the main shaft from the second gear side.
  • Page 101 1200 SPORT 4V ABS Engine • Remove the circlip. • Remove the gear of the third and fourth gears. • Remove the circlip and collect the shoulder washer. • Remove the gear of the fifth gear and collect the ball bearing cage.
  • Page 102 1200 SPORT 4V ABS Engine • Heat the shaft with a specific heater and remove the helical transmission gear. Removing the secondary shaft • Remove the transmission shaft. • Operate on the shaft from the grooved side. • Remove the shoulder washer.
  • Page 103 1200 SPORT 4V ABS Engine • Remove the circlip. • Remove the gear of the sixth gear. • Remove the circlip and collect the shoulder washer. • Remove the gear of the fourth gear and collect the ball bearing cage.
  • Page 104 1200 SPORT 4V ABS Engine • Remove the gear of the third gear and collect the ball bearing cage and the shoulder washer. • Remove the circlip. • Remove the gear of the fifth gear. • Remove the circlip, the shoulder wash- er and remove the gear of the first gear, collect the ball bearing cage.

  • Page 105: Checking The Secondary Shaft

    1200 SPORT 4V ABS Engine Checking the primary shaft Measure coaxiality of the main shaft with a dial gauge and a centring device and replace it if not complying with specifications. Characteristic Shaft coaxiality limit 0.08 mm (0.0031 in) Check transmission gears for signs of pitting and wear and replace damaged gears if necessary.
  • Page 106 1200 SPORT 4V ABS Engine Checking the forks NOTE THE FOLLOWING PROCEDURE IS VALID FOR ALL GEARBOX FORKS. • Check the transmission fork cam roller «1» and the transmission fork tooth «2» for damage, deformation and wear. • Replace the transmission fork if nec- essary.

  • Page 107: Assembling The Gearbox

    1200 SPORT 4V ABS Engine Assembling the gearbox NOTE TO REFIT, FOLLOW THE SAME INSTRUCTIONS AS FOR REMOVAL BUT IN REVERSE ORDER. REMEMBER TO REPLACE ALL SEALING RINGS, CIRCLIPS AND SAFETY RINGS PREVIOUSLY REMOVED. If the clutch is replaced, measure the length of the clutch control rod in order to use the correct rod.
  • Page 108 1200 SPORT 4V ABS Engine Generator key: 1. Alternator 2. Spacer 3. Screw 4. Screw 5. Nut 6. Belt 7. Generator control pulley 8. Nut 9. Washer 10.Magneto flywheel cotter 11.Screw 12.Nut ENG - 108...

  • Page 109: Removing The Generator

    1200 SPORT 4V ABS Engine Removing the generator • Remove the fuel tank. • Remove the control unit from its seat. • Disconnect the alternator connectors. • Undo and remove the five screws and collect the bushings. • Remove the cover.
  • Page 110 1200 SPORT 4V ABS Engine • Loosen the nut and undo the set screw so that the alternator slides down. • Completely loosen and remove the screw. • Remove the belt and the alternator with pulley. • Using a compressed air gun, unscrew and remove the nut and collect the spacer.
  • Page 111 1200 SPORT 4V ABS Engine • Unscrew and remove the eight screws. • Undo and remove the two screws. • Undo and remove the two screws. ENG - 111...
  • Page 112 1200 SPORT 4V ABS Engine • Remove the alternator frame. • Remove the sealing ring if necessary. See also Fuel tank Tensioning the belt • Remove both side fairings of the fuel tank. • Remove the right exhaust manifold. •...
  • Page 113 1200 SPORT 4V ABS Engine • Remove the engine oil radiator. • Disconnect the horn connectors. • Remove the support plate of the en- gine oil radiator. • Remove the four fixing screws of the timing system cover. ENG - 113...

  • Page 114: Installing The Generator

    1200 SPORT 4V ABS Engine • Remove the timing system cover. • Loosen the lock nut of the set screw. • By using the belt tensioning tools, ten- sion the belt to the prescribed torque. Specific tooling 020677Y Generator belt tensioner, lever for belt tensioning •...
  • Page 115 1200 SPORT 4V ABS Engine • Replace the gasket and place the al- ternator frame using the front cover in- sertion cone. • Remove the insertion cone afterwards. Specific tooling 05.91.17.30 Front cover insertion cone • Tighten the two screws.
  • Page 116 1200 SPORT 4V ABS Engine • Position the lower pulley and the spacer. • Tighten the nut to the prescribed tor- que. • Position the alternator and the timing system belt. • Position the screw and pre-tighten it. • Position the screw and tighten the nut.
  • Page 117 1200 SPORT 4V ABS Engine • Using the belt tensioning tool, tension the belt to the prescribed torque and tighten the set screw. • Remove the belt tensioning tool. • Lock the set screw in position by screwing the lock nut.
  • Page 118 1200 SPORT 4V ABS Engine Starter motor Removing the starter motor • Undo and remove the two screws and collect the washers. • Slide off the starter motor. Clutch side ENG - 118...

  • Page 119: Disassembling The Clutch

    1200 SPORT 4V ABS Engine Disassembling the clutch key: 1. Complete clutch 2. Clutch 3. Clutch bell 4. TCEI screw 5. Clutch plate 6. Sprocket 7. TCEI screw 8. Clutch thrust plate 9. Ring 10.TE flanged screw 11.Conical washer 12.Bushing 13.Rod...
  • Page 120 1200 SPORT 4V ABS Engine 20.TE flanged screw • Remove the complete gearbox. • Unscrew and remove the six screws. • Remove the start-up crown gear. • Remove the clutch housing and the friction disc. • Remove the retainer ring.
  • Page 121 1200 SPORT 4V ABS Engine • Undo and remove the six screws and collect the Belleville springs. • Remove the clutch plate. See also Removing the gearbox Checking the clutch actuator If the clutch is replaced, measure the length of the clutch control rod in order to use the correct rod.

  • Page 122: Assembling The Clutch

    1200 SPORT 4V ABS Engine 020678Y Tool for clutch rod checking CLUTCH CONTROL ROD SELECTION Specification Desc./Quantity Protrusion: 9.8 - 11.2 mm (0.386 - 0.441 in) Clutch control rod length (code 976593) = 183 mm (7.205 in) Protrusion: 8.3 - 9.7 mm (0.327 - 0.382 in) Clutch control rod length (code 976594) = 184.5 mm (7.264 in)
  • Page 123 1200 SPORT 4V ABS Engine • Once the centring tool is fitted, lock the plate with the snap ring. • Undo and remove the two screws fixing the tool. • Remove the special tool. • Place the friction disc; centre it.
  • Page 124 1200 SPORT 4V ABS Engine Head and timing key: 1. Right cylinder head 2. Stud bolt 3. Cylinder head gasket 4. Right rocking lever support 5. Screw 6. Pin 7. Nut 8. Right exhaust, left intake rocking lever 9. Left exhaust, right intake rocking lever 10.Set screw...
  • Page 125 1200 SPORT 4V ABS Engine 20.TE flanged screw 21.O-ring 22.Complete breather cover 23.TBEI screw 24.Timing system chain 25.Chain guide slider 26.Chain tensioner pad 27.Chain tensioner screw 28.Right chain tensioner 29.Left cylinder head 30.Stud bolt 31.Cylinder head gasket 32.Left rocking lever support 33.Screw...

  • Page 126: Removing The Head Cover

    1200 SPORT 4V ABS Engine Removing the head cover NOTE THE OPERATIONS DESCRIBED BELOW REFER TO ONE HEAD REMOVING ONLY BUT APPLY TO BOTH HEADS. • Disconnect the spark plug boot. • Unscrew and remove the four head cover fixing screws and collect the sealing O-rings.
  • Page 127 1200 SPORT 4V ABS Engine • Unscrew and remove the screw. • Remove the timing system upper gear bulkhead. For the right head: • Unscrew and remove the chain ten- sioner cap. • Remove the right chain tensioner. For the left head: •...
  • Page 128 1200 SPORT 4V ABS Engine • Slide off the timing system gear from the chain to remove it from the cam- shaft. • Unscrew and remove the four nuts on the stud bolts. • Remove the complete cam cap. •...
  • Page 129 1200 SPORT 4V ABS Engine • Collect the two head dowel pins. • Collect the gasket between the head and the cylinder. OPTION 02 CAUTION WHEN REMOVING THE COMPONENTS, MARK THE POSITION OF EACH PART VERY CARE- FULLY IN ORDER TO PLACE THEM IN THEIR ORIGINAL POSITION UPON FITTING.
  • Page 130 1200 SPORT 4V ABS Engine • Remove the centrifugal separator. For the right head: • Unscrew and remove the chain ten- sioner cap. • Remove the right chain tensioner. For the left head: • Unscrew and remove the screw and the washer.
  • Page 131 1200 SPORT 4V ABS Engine • Slide off the timing system gear from the chain to remove it from the cam- shaft. • Unscrew and remove the four nuts on the stud bolts. • Remove the complete cam cap. •...

  • Page 132: Cylinder Head

    1200 SPORT 4V ABS Engine • Collect the two head dowel pins. • Collect the gasket between the head and the cylinder. Cylinder head Removing the overhead camshaft CAUTION WHEN REMOVING THE COMPONENTS, MARK THE POSITION OF EACH PART VERY CARE- FULLY IN ORDER TO PLACE THEM IN THEIR ORIGINAL POSITION UPON FITTING.
  • Page 133 1200 SPORT 4V ABS Engine • Remove the camshaft. • Remove the bowls from the cam cap, and mark their position so as not inter- change them when refitting. Removing the rocker arms CAUTION WHEN REMOVING THE COMPONENTS, MARK THE POSITION OF EACH PART VERY CARE- FULLY IN ORDER TO PLACE THEM IN THEIR ORIGINAL POSITION UPON FITTING.

  • Page 134: Removing The Valves

    1200 SPORT 4V ABS Engine Removing the valves • Remove the head. • Place the special tool on the upper cap and at the centre of the head of the valve to be removed. Specific tooling 10.90.72.00 Tool for valve removal and refitting AP9100838 Tool for valve pressure plate •...

  • Page 135: Checking The Cylinder Head

    1200 SPORT 4V ABS Engine • Use a reamer to bore the holes the valve stems slide through so that the inside diameter is at the prescribed value. The interference between the seat on the head and the valve guide must be 0.046 - 0.075 mm (0.0018 - 0.0030 in)

  • Page 136: Installing The Valves

    1200 SPORT 4V ABS Engine - Replace the head in case of excessive wear or damage. Installing the valves NOTE THE FOLLOWING OPERATIONS REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH HEADS. • Place the valve guide oil seal (4) in the head.
  • Page 137 1200 SPORT 4V ABS Engine WARNING MAKE SURE THAT THE NOTCH ON THE DIPSTICK BODY FACES THE ROCKING LEVER. • Place the two rocking levers in the cam tower seats. • Place the U-bolt on the rocking levers making sure the two reference pins match the seats on the cam tower.
  • Page 138 1200 SPORT 4V ABS Engine Installing the overhead camshaft • Place the bowls in the cam tower, if those previously removed are refitted be careful not to interchange them. • Place the camshaft with the gear seat on the dowel side.
  • Page 139 1200 SPORT 4V ABS Engine Removing the phonic wheel • Remove the generator and the timing system cover. • Unscrew and remove the nut and col- lect the washer. • Remove the timing system gear on the service shaft. •...
  • Page 140 1200 SPORT 4V ABS Engine • Mark the timing chains so as not to in- vert the direction of rotation upon fit- ting. • Slide off the service shaft from the chains. • Remove both chains. See also Removing the phonic wheel Installing the service shaft •...
  • Page 141 1200 SPORT 4V ABS Engine • Partially fit the service shaft closing cap. • To screw the cap until it stops, use two M6 flanged screws larger than the orig- inal screws. • Tighten the two M6 flanged screws op- erating in stages until the cap stops against the crankcase.

  • Page 142: Cam Timing

    1200 SPORT 4V ABS Engine Installing the service shaft Cam timing • Fit the crankshaft and the service shaft on the crankcase. • Fit the cylinders. • Turn the crankshaft until the left cylin- der piston reaches the top dead centre (TDC).
  • Page 143 1200 SPORT 4V ABS Engine • Fit the timing system gear and align the reference with that on the crankshaft gear. Turn the crankshaft to align the two gears. • After shimming the timing sensor prop- erly, proceed to fit it.
  • Page 144 1200 SPORT 4V ABS Engine • Place the driving pin on the oil pump shaft. • Place the gear on the oil pump shaft. • Place the washer on the oil pump shaft. • Tighten the nut to the specified torque.
  • Page 145 1200 SPORT 4V ABS Engine • Tighten the screw with the washer to the prescribed torque. See also Installing the crankshaft Installing the service shaft Measuring air gap Measuring air gap • Undo and remove the two screws and remove the sensor.
  • Page 146 1200 SPORT 4V ABS Engine • Place the sensor on the crankcase and move it until it makes contact with the tone wheel. • Measure the clearance between the fixing plate and the crankcase with a thickness gauge. Subtract the plain washer value from this measurement to obtain the clearance between the sensor and the tone wheel.

  • Page 147: Removing The Cylinder

    1200 SPORT 4V ABS Engine 5. Middle piston ring 6. Oil scraper piston ring 7. Pin 8. Retainer ring 9. Cylinder base gasket 10.Stud bolt 11.Pin 12.Cylinder head gasket 13.Left cylinder 14.Washer 15.Chain tensioner cap 16.Washer 17.Left chain tensioner 18.Right chain tensioner...

  • Page 148: Disassembling The Piston

    1200 SPORT 4V ABS 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 149 1200 SPORT 4V ABS Engine • Lock crankshaft rotation. Specific tooling 12.91.18.01 Tool to lock the flywheel and the starting ring gear • Fit the piston. NOTE CHECK THE ORIENTATION OF THE PISTON ACCORDING TO THE REFERENCES AT THE TOP.

  • Page 150: Installing The Cylinder

    1200 SPORT 4V ABS Engine Installing the cylinder RIGHT CYLINDER • Fit the piston. • Remove the cloth used to prevent for- eign bodies from getting into the crank- case. • Turn the rings so that the coupling ends are 120 degrees from each other.
  • Page 151 1200 SPORT 4V ABS Engine • Fit the movable chain slider. • Fit the upper gear. • Fit the chain tensioner and the chain tensioner cap temporarily and keep the chain taut on the service shaft. LEFT CYLINDER • Fit the piston.

  • Page 152: Installing The Cylinder Head

    1200 SPORT 4V ABS Engine DURING THIS OPERATION, PAY ATTENTION NOT TO DAMAGE THE PISTON. Specific tooling 020674Y Piston ring clamp 020716Y Connecting rod locking • Fit the movable chain slider. • Fit the upper gear. • Fit the chain tensioner cap temporarily and keep the chain taut on the service shaft.
  • Page 153 1200 SPORT 4V ABS Engine • Fit a new O-ring in the spark plug hole. • Fit the complete cam cap. • Fix the cam cap with the four nuts on the stud bolts. • Fix the head with the two screws.
  • Page 154 1200 SPORT 4V ABS Engine • Screw two screws in the threaded holes of the timing system upper gear. • Rotate the camshaft so that its pin is aimed towards the hole in the timing system chain. • Place the gear in the chain.
  • Page 155 1200 SPORT 4V ABS Engine • Screw two screws in the threaded holes of the timing system upper gear. • Rotate the camshaft so that its pin is aimed towards the hole in the timing system chain. • Place the gear in the chain.
  • Page 156 1200 SPORT 4V ABS Engine • Fit the valves in the head, if previously removed. • Take the left cylinder piston to TDC and lock crankshaft rotation. • Determine the thickness of the gasket to be fitted between the head and the cylinder as described in the section: Shimming system.
  • Page 157 1200 SPORT 4V ABS Engine • Fix the head with the two screws. • Tighten nuts and screws to the prescri- bed torque operating diagonally and in stages. • Loosen the valve set screws. • Using a thin screwdriver relief oil pres- sure from the left cylinder chain ten- sioner.
  • Page 158 1200 SPORT 4V ABS Engine • Fit the gasket with the correct thick- ness between the head and the cylin- der. • Fit the right cylinder head. • Unscrew and remove the right chain tensioner cap. • Screw two screws in the threaded holes of the timing system upper gear.
  • Page 159 1200 SPORT 4V ABS Engine • Also place the centrifugal separator of the other head. • Place the cap. • Tighten the two screws to the prescri- bed torque. • Also place the cap of the other head. • Adjust valve clearance.

  • Page 160: Crankcase - Crankshaft

    1200 SPORT 4V ABS Engine • Place the spark plug tube. Crankcase - crankshaft Removing the crankshaft • Remove the clutch. • Remove the tone wheel and the oil pump gear. • Working from the generator side, un- screw and remove the nut.
  • Page 161 1200 SPORT 4V ABS Engine • Hold the crankshaft during flange re- moval. • With the suitable special tool, hold the flange under slight tension by tighten- ing the central screw of the tool itself, simultaneously heating the outer part of the flange for about twenty minutes.
  • Page 162 1200 SPORT 4V ABS Engine Disassembling the connecting rod • Remove both heads. • Remove the cylinders and the pistons. • Remove the oil sump. • Undo the coupling screws (A) inside the crankcase and remove the con- necting rods (B).

  • Page 163: Checking The Connecting Rod

    1200 SPORT 4V ABS Engine BALANCING SELECTION COLOURS (2) Specification Desc./Quantity Crankshaft selection colour (2) brown Type 1 to be used with brown connecting rods. Balance with a 1558 g (54.96 oz) +/- 0.25% weight fitted on the crankpin (B). Maximum imbalance allowed for each shoulder: 2 g (0.07 oz).
  • Page 164 1200 SPORT 4V ABS Engine CONNECTING ROD BEARING THICKNESS Specification Desc./Quantity 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 Desc./Quantity...
  • Page 165 1200 SPORT 4V ABS Engine Assembling the connecting rod • Lubricate the crankpin on which the connecting rods are to be fixed. • If the connecting rods are not replaced, be careful not to interchange the right connecting rod with the left one and vice versa.

  • Page 166: Installing The Crankshaft

    1200 SPORT 4V ABS Engine Installing the crankshaft • Fit the shim washer inside the crank- case with the chamfered side facing the generator side. • Lubricate the crankshaft bushing on the crankcase, generator side. • Use the sealing ring fitting tool on the flywheel-side flange to fit the sealing ring on the flange.
  • Page 167 1200 SPORT 4V ABS Engine • Spread with Loctite 510 the outer part of the flange (side of contact with the crankcase) • Place the flywheel-side flange on the crankshaft and check if the dowel pin with the O-ring is correctly placed.
  • Page 168 1200 SPORT 4V ABS Engine Refitting the crankcase halves In case the lubrication jets are removed, replace them with two new of the same type. Check that the O-ring is fitted on the jets. Do not interchange them upon refitting because they have a different length.

  • Page 169: Oil Pump

    1200 SPORT 4V ABS Engine 1. Oil radiator 2. Oil delivery pipe to heads 3. Oil delivery pipe to radiator 4. Oil pump body 5. Oil pump gasket 6. Rotor for lubrication 7. Rotor for cooling 8. Rotor control shaft 9.
  • Page 170 1200 SPORT 4V ABS Engine • Remove the nipple - oil pump fitting. • Bring the left cylinder piston to the TDC in combustion phase. • Mark a reference on the oil pump con- trol gear and another on the driven gear so as to place them correctly again upon refitting.
  • Page 171 1200 SPORT 4V ABS Engine • Remove the driving pin. • Unscrew and remove the three screws. • Remove the oil pump. • Remove the gasket between the crankcase and the oil pump. See also Removing the generator Installing •...
  • Page 172 1200 SPORT 4V ABS Engine • Fit the oil pump. • Tighten the three oil pump fixing screws. • Place the driving pin on the oil pump shaft. • Place the gear on the oil pump shaft. • Place the washer on the oil pump shaft.
  • Page 173 1200 SPORT 4V ABS Engine • Place the oil pump control gear on the crankshaft and align its reference with that marked during the removal phase on the oil pump driven gear. • Tighten the nut to the specified torque.
  • Page 174 1200 SPORT 4V ABS Engine Oil sump RANKCASE AND pos. Description Type Quantity Torque Notes Stud bolt M8x75 10 Nm (7.37 lb ft) Stud bolt M8x66 10 Nm (7.37 lb ft) Crankshaft rear support flange fixing screw M8x25 26 Nm (19.18 lb ft) Oil cap on the crankcase 25 Nm (18.44 lb ft)

  • Page 175: Specific Tooling

    1200 SPORT 4V ABS Engine IL SUMP COMPONENTS pos. Description Type Quantity Torque Notes Cover on the flange under the crankcase 40 Nm (29.50 lb ft) Oil filter joint 10 Nm (7.37 lb ft) Loctite 243 Oil sump pipe 20 Nm (14.75 lb ft)
  • Page 176 1200 SPORT 4V ABS Engine • Undo and remove the fourteen screws fixing the oil sump to the engine crank- case. • Unscrew and remove the four screws. • Remove the flange. ENG - 176...
  • Page 177 1200 SPORT 4V ABS Engine • Unscrew and remove the two screws. • Remove both side filters.. • Unscrew and remove the cap. • Remove the thermostatic valve. • Unscrew and remove the overpressure valve plug. • Remove the overpressure valve ele-...
  • Page 178 1200 SPORT 4V ABS Engine Refitting the oil sump • Place the overpressure valve elements correctly. • Tighten the overpressure valve plug. • Place the thermostatic valve. CHECK THAT THE ENGINE OIL PASSAGE HOLE IS NOT CLOGGED. ENG - 178...
  • Page 179 1200 SPORT 4V ABS Engine • Tighten the thermostatic valve plug. • Place a new gasket between the crank- case and the flange. • Insert the flange • Fix the flange with the four screws. • Insert the lubrication oil intake filter...
  • Page 180 1200 SPORT 4V ABS Engine • Check that on the oil pump are the OR rings. • Insert the cooling oil intake filter. • Fix both filters by tightening the two screws to the prescribed torque. • Fit a new oil filter by tightening it to the prescribed torque.
  • Page 181 1200 SPORT 4V ABS Engine • Place the oil sump. • Tighten the fourteen screws to the pre- scribed torque. • Add engine oil up to the correct level. ENG - 181...

  • Page 182: Index Of Topics

    INDEX OF TOPICS P SUPP OWER SUPPLY...

  • Page 183: Circuit Diagram

    1200 SPORT 4V ABS Power supply Circuit diagram Key: 1. Full fuel tank 2. Fuel pipe 3. Throttle body 4. Joint 5. Three-way joint 6. Pipe Injection P SUPP - 183...
  • Page 184 1200 SPORT 4V ABS 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 185 1200 SPORT 4V ABS Power supply 13 Lambda probe 14 Fall sensor THROTTLE BODY PIPES LAYING Pipes from the throttle body to the idle motor should be laid so that the shaped part is inserted in the air filter casing.
  • Page 186 1200 SPORT 4V ABS Power supply • Turn on the scanner. • Screw the joints connecting the vacuometer pipes on the inlet pipe holes. • Connect the vacuometer pipes to the relative joints. • Set the key to ON. •...

  • Page 187: Recovery Function

    1200 SPORT 4V ABS Power supply Otherwise, open only the screw with higher depression, using the by-pass screws, to compensate. If there is a larger difference: • act on the set screw of the throttle body connecting rod to reduce the pressure difference in the two pipes.
  • Page 188 1200 SPORT 4V ABS Power supply Iso screen page This screen page shows general data regarding the control unit, for example software type, map- ping, control unit programming date ISO DISPLAY Specification Desc./Quantity Mapping Engine parameter reading screen page ENGINE PARAMETER READING...

  • Page 189: Device Status

    1200 SPORT 4V ABS Power supply Specification Desc./Quantity Target engine revs 1150 rpm (approximate values) Parameter valid at idle, setting depends especially on the en- gine temperature: the control unit will try to keep the engine running at this revs, acting on the ignition advance and the...

  • Page 190: Errors Display

    1200 SPORT 4V ABS Power supply Devices activation screen page DEVICES ACTIVATION This screen page is used to delete errors in the control unit memory and to activate some systems controlled by the control unit. DEVICES ACTIVATION Specification Desc./Quantity Left coil operation for 2.5 m, 5 times...

  • Page 191: Adjustable Parameters

    1200 SPORT 4V ABS Power supply Specification Desc./Quantity Lambda probe Possible short circuit on the earth lead, battery or open circuit or plausibility: recovery function hardly noticeable for customer. Left injector Possible short circuit in the earth lead, battery or open circuit.
  • Page 192 INDEX OF TOPICS SUSP USPENSIONS...

  • Page 193: Front Fork

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

  • Page 194: Removing The Fork Legs

    1200 SPORT 4V ABS Suspensions 15.Right pumping member rod 16.Lock nut 17.Washer 18.Preloading pipe 19.Spring 20.Lower bushing 21.Stem 22.Complete cap 23.Screw with O-ring 24.Sticker 25.Pin 26.Spring 27.Ball 28.O-ring 29.Set screw 30.O-ring Removing the fork legs • Unscrew the screws fixing the front mudguard and remove it.
  • Page 195 1200 SPORT 4V ABS Suspensions • Unscrew the screws fixing the front brake callipers and remove them from their seat. • Support the front part of the vehicle. • Remove the nut fixing the wheel pin. • Collect the sealing washer.
  • Page 196 1200 SPORT 4V ABS Suspensions • Remove the wheel pin by inserting a screwdriver in the holes on the pin. • During extraction, support the wheel and then remove it. • Collect the spacer from the front wheel right side.

  • Page 197: Draining Oil

    1200 SPORT 4V ABS Suspensions • Remove the fork stem. Draining oil To drain out the oil follow these operations: • Remove the fork. • Unscrew the complete upper closing cap. Pay attention to the possible thrust that the spring can cause to the loosened cap.

  • Page 198: Disassembling The Fork

    1200 SPORT 4V ABS Suspensions • Drain out all the oil inside the stem. • Collect the preload tube. NOTE FOR EASY DRAINAGE OF THE OIL INSIDE THE PISTON ROD, PRESS THE STANCHION IN THE WHEEL HOLDER SLEEVE TO PUMP OIL OUT.
  • Page 199 1200 SPORT 4V ABS 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.

  • Page 200: Checking The Components

    1200 SPORT 4V ABS Suspensions Checking the components Stem Check the sliding surface for scorings and/or scratches. These scorings can be eliminated by rubbing them with wet sandpaper (grain 1). If the scorings are deep, replace the stem. Use a dial gauge to check that the stem bending is below the limit value.
  • Page 201 1200 SPORT 4V ABS Suspensions Check that there are no damages and/or cracks; otherwise, replace it. Spring Check the spring is in good conditions. Check that the following components are in good conditions: • upper bushing; • lower bushing; •...
  • Page 202 1200 SPORT 4V ABS Suspensions • O-Ring on the cap. Reassembling the fork CAUTION ALL COMPONENTS MUST BE CAREFULLY WASHED AND DRIED WITH COMPRESSED AIR BE- FORE REFITTING. • Carry out any necessary service oper- ation. • On the stem, fit the entire pumping unit together with the lock nut and the washer.
  • Page 203 1200 SPORT 4V ABS Suspensions • Screw the bottom screw and tighten it to the prescribed torque. • Insert the cap and the well lubricated sealing ring in the stem. • Use a suitable inserting tool to push the sealing ring in the fork leg until it stops.

  • Page 204: Filling Oil

    1200 SPORT 4V ABS Suspensions • Fit the dust scraper. Filling oil • Place the sleeve upright in a vice fitted with protection jaws. • Compress the sleeve in the stem. • Pour part of the fork oil into the sleeve.

  • Page 205: Installing The Fork Legs

    1200 SPORT 4V ABS Suspensions • Place the cap on the bearing tube tak- ing care not to damage the O-ring. • Then, tighten the cap to the prescribed torque. Installing the fork legs • Insert the fork stem in position.
  • Page 206 1200 SPORT 4V ABS Suspensions • Tighten the screws on the fork plates to the prescribed torque. • Remove the wheel pin • Place the right side wheel with spacer. • Insert the pin. • Tighten the terminal screws (nut side)
  • Page 207 1200 SPORT 4V ABS Suspensions • Insert the sealing washer onto the wheel axle. • Tighten the wheel axle fixing nut to the specified torque • Make sure that the stanchions are aligned by working with the fork. • Tighten the terminal screws that lock the wheel pin to the prescribed torque.

  • Page 208: Steering Bearing

    1200 SPORT 4V ABS Suspensions • Fit the front mud guard. Steering bearing Adjusting play • Remove the top fairing. • Unscrew and remove the screws and move the instrument panel forward. • Unscrew and remove the screws and collect the U-bolts, holding the handle- bar.
  • Page 209 1200 SPORT 4V ABS Suspensions • Working on both sides, unscrew and remove the upper plate fixing screw on the fork stems. • Lift the fork upper plate sliding it off from the stems. • Rivet the safety washer on the head- stock.
  • Page 210 1200 SPORT 4V ABS Suspensions • Using the suitable special tool, set the preloading of the steering bearings. Specific tooling AP8140190 Tool for steering tightening SUSP - 210...

  • Page 211: Index Of Topics

    INDEX OF TOPICS CHAS HASSIS...

  • Page 212: Swinging Arm

    1200 SPORT 4V ABS 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 213 1200 SPORT 4V ABS 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 214 1200 SPORT 4V ABS Chassis • Loosen the ring nut. Specific tooling GU14912603 Hook spanner for fixing ring nut of the clutch shaft internal body • Helped by a second operator, remove the pin and remove the swingarm to- gether with the cardan shaft.
  • Page 215 1200 SPORT 4V ABS 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 216 1200 SPORT 4V ABS 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 217 1200 SPORT 4V ABS Chassis • Place the dust-protection ring between the rim and the cardan shaft taking care to mount it with the collar facing the transmission unit. • Place the rear wheel on the swingarm. • Tighten the four screws with their spacers and the dust-protection ring.
  • Page 218 1200 SPORT 4V ABS Chassis • Undo and remove the four screws. • Remove the transmission casing slid- ing off the universal joint. Checking Casing unit removal CHAS - 218...
  • Page 219 1200 SPORT 4V ABS 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 - 219...
  • Page 220 1200 SPORT 4V ABS Chassis Collect the ring (15). Remove the screws (7). Remove the casing (4). Remove the clamp (12). Remove the cap (14). CHAS - 220...
  • Page 221 1200 SPORT 4V ABS Chassis Collect the ring (13). Remove the support unit (8). 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 222 1200 SPORT 4V ABS Chassis Heat the casing. Insert the support group in the casing. Assemble the cap and the ring. Fit the cap on the support. Fit the clamp. CHAS - 222...
  • Page 223 1200 SPORT 4V ABS Chassis Screw the clamp with the specific pliers. Apply the prescribed sealant to the casing. Fit a new sealing ring using the buffer. Lubricate the sealing ring. Assemble two centring stud bolts with M8 thread in the threaded holes of the casing as shown in the picture.
  • Page 224 1200 SPORT 4V ABS Chassis Fit the casing. Remove the two dowel pins. Assemble the fixing screws (7). Tighten the screws (7) to the prescribed torque. Remove excessive sealant. Assemble the ring to the casing. Tighten the fixing screws to the prescribed torque.
  • Page 225 1200 SPORT 4V ABS Chassis Fit the cap with the washer. Screw the cap to the prescribed torque. Fit the breather with the washer. Screw the breather to the prescribed torque. Fill the transmission with the prescribed oil. Fit the cap with the washer.
  • Page 226 1200 SPORT 4V ABS Chassis Fit the cap in its seat. Wheel axle unit Gruppo asse ruota Removal Remove the bearing from the wheel axle with a suitable extractor. Turn the unit over. Remove the bearing from the wheel axle with a suitable extractor.
  • Page 227 1200 SPORT 4V ABS Chassis Assemble the bearings to the wheel axle. Turn the unit over. Assemble the bearings to the wheel axle. Pinion unit Pinion unit Removal Remove the stop ring (1) from the ring nut. Unscrew the ring nut (2) with the special spanner (s4).
  • Page 228 1200 SPORT 4V ABS 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 229 1200 SPORT 4V ABS Chassis Tighten the ring nut (2) with the special spanner (s4) to the prescribe torque. Insert the stop ring (1) in the ring nut (2) in the in- dicated direction. Assembly position of the stop ring (1).
  • Page 230 1200 SPORT 4V ABS 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 231 1200 SPORT 4V ABS 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 232: Troubleshooting

    1200 SPORT 4V ABS Chassis Manually assemble the new sealing rings (2) and (7). Assemble the bushing (1). Drive the bushing (1) in with a plastic hammer. Turn the support (5) over and assemble the other bushing (8). TROUBLESHOOTING Possible Cause Operation 1.
  • Page 233 1200 SPORT 4V ABS 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 234 1200 SPORT 4V ABS Chassis • Place the rear wheel on the swingarm. • Tighten the four screws with their spacers and the dust-protection ring. • Place the cover. • Place the rear brake calliper on the disc and the brake pipe on the swingarm.
  • Page 235 1200 SPORT 4V ABS Chassis 8. Left clamp 9. Expansion chamber 10.Rubber ring 11.Washer for shafts 12.Lambda probe 13.Spring 14.Gasket 15.Clamp 16.Silencer 17.Screw 18.Silencer fixing bushing 19.Muffler rubber ring 20.Spacer 21.Nut 22.Screw 23.Washer Removing the tail pipe • Loosen the sealing clamp between the exhaust and the central manifold.
  • Page 236 1200 SPORT 4V ABS Chassis • Remove the exhaust end. Removing the catalytic converter • Remove the exhaust end and the ex- haust manifolds. • Remove the starter motor protection in order to disconnect the lambda probe connector. • Slide off the retaining hooks from the rubber rings.

  • Page 237: Removing The Exhaust Manifold

    1200 SPORT 4V ABS Chassis Removing the exhaust manifold • Unscrew and remove the two nuts on the head exhaust stud bolts. • Retrieve the washers. • Loosen the clamp. • Remove the exhaust manifold. Engine oil cooler Removing •...
  • Page 238 1200 SPORT 4V ABS Chassis • Unscrew and remove the screw and collect the washer. • Unscrew and remove the nut. • Remove the front tank protection. • Unscrew and remove the oil cooling ra- diator upper fixing stud bolt.
  • Page 239 1200 SPORT 4V ABS Chassis • Start the vehicle and let the engine run for a few minutes so that the oil circu- lates and fills the radiator internal ducts. • Stop the engine and check the oil level with the dipstick (1).

  • Page 240: Index Of Topics

    INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
  • Page 241 1200 SPORT 4V ABS Braking system Interventions rules CAUTION THE FRONT BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE SPECIFICATIONS OF THE SYSTEM. Foreword key: 1. Front brake pipe 2. Oil pipe screw 3. Aluminium gasket 4. Front brake pipe 5.

  • Page 242: Operating Diagram

    1200 SPORT 4V ABS Braking system Operating diagram key: The black arrow indicates brake fluid path when the ABS system is not working. The white arrow indicates the brake fluid path when the ABS system is working. 2) ABS Control unit...

  • Page 243: Abs Operation

    1200 SPORT 4V ABS Braking system 16) Front inlet valve 17) Rear inlet valve ABS OPERATION General specifications: • The front circuit is similar to the rear circuit. • The ABS inlet valve (16 - 17) is normally open and it is closed only when the system inter- venes to avoid wheel locking.
  • Page 244 1200 SPORT 4V ABS Braking system ABS SYSTEM DESCRIPTION The ABS system is a device to avoid wheels lock- ing in case of emergency braking, increasing ve- hicle braking stability when compared to a tradi- tional braking system. Sometimes when the brake is operated, the tyre locks with a consequent loss of grip, which makes it difficult to control the vehicle.
  • Page 245 1200 SPORT 4V ABS Braking system At engine start-up, the ABS warning light (7) comes on and remains on provided that the vehicle does not exceed 5 km/h (3.1 mph). If the warning light remains on permanently, it means that a mal- function has been detected and the ABS has been deactivated.
  • Page 246 1200 SPORT 4V ABS Braking system Abs screen pages ISO screen page This screen page shows general data regarding the control unit, for example software type, map- ping, control unit programming date ISO SCREEN PAGE Specification Desc./Quantity ISO Code C1EF...

  • Page 247: Errors Display

    1200 SPORT 4V ABS Braking system 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).
  • Page 248 1200 SPORT 4V ABS Braking system ERRORS DISPLAY Specification Desc./Quantity Front speed sensor open circuit or short circuit - see (DIAGNOSIS) Rear speed sensor open circuit or short circuit - see (DIAGNOSIS) Front speed sensor coherence - see (DIAGNOSIS) Rear speed sensor coherence...
  • Page 249 1200 SPORT 4V ABS Braking system If functioning is correct, proceed to the next check Checks: check the 10A fuse and wiring coming from the key panel (disconnect the ABS module con- nector and with the key set to ON, check if there is battery voltage in pin 18). Solution: restore the fuse...
  • Page 250 1200 SPORT 4V ABS Braking system Checks: check the tone wheel is not distorted (it should not be deformed or damaged). Solution: replace tone wheel If functioning is correct, proceed to the next check Checks: check the speed sensor position and integrity. Solution: position the speed sensor correctly or replace it.
  • Page 251 1200 SPORT 4V ABS Braking system Description of the defect: the control unit detects a failure in the electric supply voltage. Checks: check if the voltage is too low (below 9.4V. Solution: charge or replace the battery. If functioning is correct, proceed to the next check Checks: check if the voltage is too high (over 16.8V) Solution: replace the voltage regulator...

  • Page 252: Front Brake Pads

    1200 SPORT 4V ABS Braking system plungers. The four nipples (1 - 2) in the ABS control unit should be unscrewed only when the unit is replaced. CAUTION WHEN THE ABS CONTROL UNIT IS REPLACED, IT IS SUPPLIED ALREADY FILLED WITH BRAKE FLUID;...
  • Page 253 1200 SPORT 4V ABS Braking system Removal • Turn the pins and remove both cotter pins. • Remove both pins. • Remove the vibration-damping plate. • Extract one pad at a time. CAUTION AFTER REMOVING THE PADS, DO NOT OPERATE THE...

  • Page 254: Rear Brake Pads

    1200 SPORT 4V ABS Braking system Installing • Insert two new pads, placing them so that the holes are aligned with the cal- liper holes. CAUTION ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED INSIDE THE CALLIPER.
  • Page 255 1200 SPORT 4V ABS Braking system Removal • Free the brake pipe and the throttle grip cable from the clamps. • Undo and remove the two screws. • Remove the brake calliper from the disc. • Turn the pin and pull out the cotter pin.
  • Page 256 1200 SPORT 4V ABS Braking system • Extract one pad at a time. CAUTION AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS. Installing •...
  • Page 257 1200 SPORT 4V ABS Braking system Bleeding the braking system Front Any air trapped in the hydraulic circuit acts as a cushion, absorbing much of the pressure applied by the brake pump and minimising the braking power of the calliper.
  • Page 258 1200 SPORT 4V ABS 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 259 1200 SPORT 4V ABS 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 260: Index Of Topics

    INDEX OF TOPICS BODYW ODYWORK...
  • Page 261 1200 SPORT 4V ABS Bodywork Headlight assy. REMOVAL OF FRONT HEADLIGHT ASSEM- • On both sides, undo and remove the two lateral screws (1). • On both sides, undo and remove the two screws (2) on the instrument panel. Support the front headlight assembly then remove from its mountings.
  • Page 262 1200 SPORT 4V ABS Bodywork • Unscrew and remove the rear upper screw and collect the nut. • Unscrew and remove the front upper screw. • Remove the air filter housing. • Disconnect the connector of the rear brake lever switch and release it from the clamps.
  • Page 263 1200 SPORT 4V ABS Bodywork • Unscrew and remove the rear upper screw and collect the nut. • Unscrew and remove the front upper screw. • Unscrew and remove the screw and remove the left footrest plate. Air box •...
  • Page 264 1200 SPORT 4V ABS Bodywork • Unscrew and remove the two screws from the oil vapour recovery reservoir. • Release the clamp. • Slide off the pipe. • Move the oil vapour recovery reservoir aside. • Unscrew and remove the two front screws from the air filter casing.
  • Page 265 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 266 1200 SPORT 4V ABS 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 267: Road Test

    1200 SPORT 4V ABS 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 268: Static Test

    1200 SPORT 4V ABS 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 269 ABS: 241, 245, 246 Air filter: 37 Air temperature sensor: 61, 74 Alternator: Battery: 49, 56 Brake: 252, 254 Brake pads: 252, 254 Catalytic converter: 236 Centre stand: Clutch: 71, 118, 119, 121, 122, 161 Coil: 67 Connectors: 76 Crankcase: 20, 160, 168 Crankshaft: 20, 141, 145, 160, 162, 166 Cylinder: 18, 126, 132, 135, 147, 150, 152, 162 Desmodromic drum: 105...
  • Page 270 Identification: 10 Instrument panel: 74 Maintenance: 8, 30, 252 Maintenance Table: Oil filter: 35 Oil pressure sensor: 69 Oil sump: 174, 175, 178 Primary shaft: 100, 105, 106 Rear wheel: Recommended products: 21, 216 Run/Stop switch: 75 Scheduled maintenance: 30 Secondary shaft: 102, 105, 106 Side stand: 72 Side stand sensor: 72...

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