Page 1 SERVICE STATION MANUAL 854326 Norge 1200...
Page 2 Countries. Third party products or services referred to in this manual should be considered only informative and are not binding. Moto Guzzi s.p.a. shall not be liable for any functions or use of these products.
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...
Page 7 INDEX OF TOPICS CHAR HARACTERISTICS...
Page 8: Safety Rules
Norge 1200 Characteristics Rules Safety rules Carbon monoxide If you need to keep the engine running in order to carry out any procedure, please ensure that you do so in an open or very well ventilated area. Never let the engine run in an enclosed area. If you do work in an enclosed area, make sure to use a smoke-extraction system.
Page 9: Maintenance Rules
Norge 1200 Characteristics BRAKE AND CLUTCH FLUIDS CAN DAMAGE PLASTIC OR RUBBER PAINTED SURFACES. WHEN SERVICING THE BRAKING OR THE CLUTCH SYSTEM PROTECT THESE COMPONENTS WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THE SYS- TEMS. BRAKE AND CLUTCH FLUIDS ARE EXTREMELY HARMFUL FOR YOUR EYES. IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THEM IMMEDIATELY WITH ABUN- DANT COLD, CLEAN WATER AND SEEK MEDICAL ADVICE IMMEDIATELY.
Page 10: Electric Connectors
CAUTION BEARINGS MUST BE ABLE TO ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTH- ERWISE THEY NEED REPLACING. • Only use ORIGINAL Moto Guzzi SPARE PARTS. • Comply with lubricant and consumables usage guidelines. • Lubricate parts (whenever possible) before reassembling them.
Page 11 That is to permit the adequate adjustment of the pad friction material to the brake discs. AFTER THE SPECIFIED MILEAGE, TAKE THE VEHICLE TO AN OFFICIAL Moto Guzzi DEALER FOR THE CHECKS INDICATED IN THE "AFTER-RUN" TABLE IN THE SCHEDULED MAINTE- NANCE SECTION TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHI- CLE.
Page 12: Engine Number
Norge 1200 Characteristics Vehicle identification SERIAL NUMBER POSITION These numbers are necessary for vehicle regis- tration. NOTE ALTERING IDENTIFICATION NUMBERS CAN BE SERIOUSLY PUNISHED BY LAW, PARTIC- ULARLY MODIFYING THE CHASSIS NUMBER WILL IMMEDIATELY INVALIDATE THE WAR- RANTY. ENGINE NUMBER The engine number is stamped on the left side, close to the engine oil level check cap.
Page 13 Norge 1200 Characteristics Specification Desc./Quantity Wheelbase 1495 mm (58.8 in) Kerb weight 246 kg (542 pounds) Engine ENGINE Specification Desc./Quantity Type 90° transversal V-twin, four stroke Cylinder quantity Cylinder layout 90° V Bore / stroke 95 x 81.2 mm (3.74 x 3.20 in) Cubic capacity 1151 cm³...
Page 14 Norge 1200 Characteristics Capacities CAPACITY Specification Desc./Quantity Engine oil Oil and oil filter change 3600 cm³ (219 cu.in) Gearbox oil 500 cm³ (30.5 cu in) Transmission oil 380 cm³ (23.2 cu in) Fuel (reserve included) 23 l (6.1 gal) Fuel reserve 4 l (1.06 gal)
Page 15: Wheels And Tyres
Norge 1200 Characteristics Specification Desc./Quantity Trail 120 mm (4.72 in) Front hydraulic telescopic fork; Ø 45 mm (1.77 in) Wheel travel 120 mm (4.72 in) Rear single arm suspension with progressive linkage, single shock absorber with adjustable rebound and ergonomic knob for spring preloading adjust- ment.
Page 16: Tightening Torques
Norge 1200 Characteristics Specification Desc./Quantity Inflation pressure with passenger (rear) 2.8 bar (280 kPa) (40.6 PSI) Supply UPPLY Specification Desc./Quantity Fuel premium unleaded petrol, minimum octane rating of 95 (NORM) and 85 (NOMM) Throttle body diffuser Ø 45 mm (1.77 in)
Page 17: Oil Pump
Norge 1200 Characteristics Name Torque in Nm Oil sump lower screw - TCEI M6x30 (4) 10 Nm (7.38 lbf ft) Oil sump screw - TCEI M6x55 (14) 10 Nm (7.38 lbf ft) Oil sump screw - TCEI M6x60 (2) 10 Nm (7.38 lbf ft) Oil drainage plug - M10x1 (1) 20 Nm (14.75 lbf ft)
Page 18 Norge 1200 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 steel M5x16 TBEI flanged screw...
Page 19 Norge 1200 Characteristics Name Torque in Nm Fork stem to lower / upper plate retainer 25 Nm Headstock ring nut 40 Nm Headstock counter ring nut manual + 90 degrees Upper plate fixing cover 100 Nm Fork hubs closing 10 Nm...
Page 20 Norge 1200 Characteristics Name Torque in Nm Brake pump retainer 10 Nm HANDLEBAR AND CONTROLS Name Torque in Nm Half-handlebar to steering plate retainer 25 Nm Handlebar pipes to half-handlebar retainer 25 Nm Anti-vibration weights retainer 10 Nm ELECTRICAL SYSTEM...
Page 21 Norge 1200 Characteristics Name Torque in Nm License plate lamp to license plate holder retainer 4 Nm FINISHING Name Torque in Nm Ignition lock retainer - shear head screw - Nm Ignition lock retainer 25 Nm SWING ARM Name Torque in Nm...
Page 22: Piston Rings
Norge 1200 Characteristics Piston rings Check the sealing piston rings and the oil scraper. On each piston there are: 1 top piston ring; 1 middle stepped piston ring; 1 oil scraper piston ring. The ends of the fitted piston rings are out of phase.
Page 23 Norge 1200 Characteristics Specification Desc./Quantity fitting clearance 0.025 - 0.066 mm (0.00098 ÷ 0.00260 inch) TAPPET-SEAT COUPLING ON CRANKCASE DATA (PRODUCTION) Specification Desc./Quantity Seats diameter 22.021 - 22.000 mm (0.86697 ÷ 0.86614 inch) Tappet external diameter 21.996 - 21.978 mm (0.86598 ÷...
Page 24 Norge 1200 Characteristics CHAR - 18...
Page 25: Index Of Topics
INDEX OF TOPICS S-TOOLS PECIAL TOOLS...
Page 26: Special Tools
Norge 1200 Special tools SPECIAL TOOLS Stores code Description 05.94.86.30 Belt tension tool 05.91.17.30 Front cover insertion cone 05.91.25.30 Gearbox opening 05.90.19.30 Inner spark plug removal 05.92.80.30 Piston ring clamp 05.92.72.30 Timing system cover sealing ring punch S-TOOLS - 2...
Page 27 Norge 1200 Special tools Stores code Description 01.92.91.00 Wrench for removing the cover on sump and filter 05.90.25.30 Gearbox support 19.92.96.00 Graduated dial to control ignition timing 17.94.75.60 Arrow to control ignition timing 12.91.18.01 Tool to lock flywheel and start-up crown gear 12.91.36.00...
Page 28 Norge 1200 Special tools Stores code Description 10.90.72.00 Tool for valve removal and refit- ting 30.90.65.10 Tool for clutch fitting 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 together with sealing ring on the crankshaft 19.92.71.00...
Page 29 Norge 1200 Special tools Stores code Description 981006 Graduated dial hub 05.91.26.30 Tool for tightening the fork pin ring nut - clutch hub AP8140190 Tool for steering tightening 000019663300 Tool for clutch shaft removal 30.91.28.10 Clutch body locking 05.90.27.30 Gearbox support...
Page 30 Norge 1200 Special tools Stores code Description 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 05.90.27.36 Bevel gear pair support S-TOOLS - 6...
Page 31: Maintenance
INDEX OF TOPICS MAIN AINTENANCE...
Page 32: Maintenance Chart
Norge 1200 Maintenance Maintenance chart NOTE CARRY OUT THE MAINTENANCE OPERATIONS AT HALF THE INTERVALS SHOWN IF THE VE- HICLE IS USED IN WET OR DUSTY AREAS, OFF ROAD OR FOR SPORTS APPLICATIONS. AT EVERY START-UP Action Engine oil pressure warning light - check and clean, adjust, grease or replace if necessary...
Page 33: Transmission Fluid
Norge 1200 Maintenance Action Clutch wear - Check and clean, adjust, grease or replace if necessary EVERY 10,000 (6250 12 MONTHS Action Outer spark plugs - Replace Idle mixture (CO) - Check and clean, adjust, grease or replace if necessary...
Page 34 Norge 1200 Maintenance Check • Keep the vehicle upright with both wheels on the ground. • Unscrew and remove the level plug (1). • The level is correct if the oil is close to the hole of the level plug (1).
Page 35: Engine Oil
Norge 1200 Maintenance • Screw and tighten the caps (1 - 2). Engine oil Check Check the engine oil level frequently. To check: ENGINE OIL LEVEL MUST BE CHECKED WHEN THE ENGINE IS WARM. IF YOU CHECK LEVEL WHEN THE ENGINE IS COLD, OIL LEVEL COULD TEMPORARILY DROP BELOW THE "MIN"...
Page 36 Norge 1200 Maintenance • Pull the filler plug / oil level dipstick (1) straight out. • Wipe the oil level dipstick (1) clean and reinsert it. • Pull it out again and check the oil level. • The oil level is correct when it is close to the "MAX"...
Page 37: Checking And Topping Up
Norge 1200 Maintenance Engine oil filter • Unscrew and remove the engine oil fil- ter from its seat. NOTE NEVER REUSE A FILTER. • Spread a thin layer of oil on the sealing ring of the new engine oil filter.
Page 38: Air Filter
Norge 1200 Maintenance DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCE TO THE FLUID. WHEN USING A FUNNEL OR ANY OTHER ELEMENT, MAKE SURE IT IS PERFECTLY CLEAN. Replacement NOTE HOT OIL IS MORE FLUID AND WILL DRAIN OUT MORE EASILY AND COMPLETELY.
Page 39: Checking The Valve Clearance
Norge 1200 Maintenance • Slide off the oil breather pipe. • Unscrew and remove the five screws. • Lift the filter casing cover. • Remove the acoustic insulation panel. • Remove the air filter. • Cover the inlet duct with a clean cloth so that no foreign bodies could get into.
Page 40: Braking System
Norge 1200 Maintenance • Remove the fuel tank. • Unscrew and remove the two screws. • Remove the spark plugs protection. • Disconnect both spark plug tubes. • Unscrew and remove the eight screws. • Remove the head cover. •...
Page 41 Norge 1200 Maintenance • For the rear brake, keep the vehicle upright so that the fluid in the reservoir is at the same level with the plug. • Make sure that the fluid level in the reservoir is above the "MIN" reference mark:...
Page 42 CHECK BRAKING EFFICIENCY. IN CASE OF EXCESSIVE TRAVEL OF THE BRAKE LEVER OR POOR PERFORMANCE OF THE BRAKING SYSTEM, TAKE YOUR VEHICLE TO AN Official Moto Guzzi Dealer, AS IT MAY BE NECESSARY TO PURGE THE AIR IN THE SYSTEM. MAIN - 12...
Page 43: Electrical System
INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 44 Norge 1200 Electrical system Components arrangement Key: 1 Coil 2 Instrument panel 3 Fuel pump 4 Injector ELE SYS - 2...
Page 45: Electrical System Installation
Norge 1200 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 Secondary fuses 14 Head temperature sensor 15 Engine control unit...
Page 46: General Wiring Diagram
Norge 1200 Electrical system General wiring diagram Key: 1 Multiple connectors 2 Clutch switch 3 Start-up relay ELE SYS - 4...
Page 47 Norge 1200 Electrical system 4 Low-beam lights relay 5 High-beam lights relay 6 Right light switch (RUN /OFF / START / HAZARD) 7 GPS connector 8 Horn 9 Left light switch 10 Instrument panel air temperature thermistor 11 Instrument panel...
Page 48 Norge 1200 Electrical system 42 Right cylinder outer spark plug 43 Left cylinder inner spark plug 44 Left cylinder outer spark plug 45 Right cylinder double coil 46 Left cylinder double coil 47 Right injector 48 Left injector 49 -...
Page 49: Enter New Code
Norge 1200 Electrical system V green Vi violet Checks and inspections 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 50 Norge 1200 Electrical system Engine Temperature Error DC Gnd ECU 15 Air Temperature Error DC V DC ECU 16 Air Temperature Error DC Gnd ECU 17 Low Battery Error ECU 20 Lambda Probe Error ECU 21 Coil 1 Error DC V DC ECU 22...
Page 51 Use the Ditech connector in the Axone 2000 Apri- lia-Moto Guzzi package to connect to the Axone cable. KEY CHANGE FUNCTION This function can be used: 1) if one key is lost;...
Page 52: Checking The Stator
Norge 1200 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 53: Front Headlamp
Norge 1200 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 SECONDARY FUSES A - Stop, horn, Hazard button lighting, relay coil lights, windshield electric motor (if fitted) (15 A).
Page 54: Main Fuses
Norge 1200 Electrical system MAIN FUSES 1 - From battery to voltage regulator (40 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 55 Norge 1200 Electrical system 17 Stepper motor (+) 18 Stepper motor (-) 19 Stepper motor (-) 20 5V power supply (NTC sensors) 21 Not used 22 Not used 23 Neutral sensor signal 24 Not used 25 Engine revolution sensor signal...
Page 56 Norge 1200 Electrical system 14 Not used 15 Not used 16 K line (diagnosis) 17 Power supply from main relay 18 Not used 19 Not used 20 CAN - H line (ccm/instrument panel) 21 Not used 22 Oxygen probe signal...
Page 57 Norge 1200 Electrical system 12 ABS warning light check 13 Not used 14 ABS deactivation switch 15 Not used 16 Front (ABS) speed sensor (signal / earth con- nection) 17 Not used 18 Switch 19 Rear (ABS) speed sensor (signal / earth con-...
Page 58: Front Speed Sensor
Norge 1200 Electrical system Speed sensor FRONT SPEED SENSOR It is used by the ABS module, and then by the ECU and the instrument panel. Differential Hall effect sensor. 2-pin connector (Supply / Signal-Earth connec- tion). REAR SPEED SENSOR It is used exclusively by the ABS module.
Page 59: Throttle Position Sensor
Norge 1200 Electrical system Throttle position sensor Output voltage 0.55 - 4.4 V (variable depending on the position of the throttle valve, to be measured between pins C and A) Engine temperature sensor This sensor, 5V powered, features NTC specifica-...
Page 60: Air Temperature Sensor
Norge 1200 Electrical system Air temperature sensor NTC type sensor IR TEMPERATURE SENSOR RESISTANCE Specification Desc./Quantity Resistance at -40 °C (-104 °F) 100.950 kOhm Resistance at 0 °C (32 °F) 9.750 kOhm Resistance at 10 °C (50 °F) 5.970 kOhm Resistance at 20 °C (68 °F)
Page 61: Engine Oil Pressure Sensor
Norge 1200 Electrical system 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 There is a failure in the oil pressure sensor when it is detected as not conducting (open) with the en- gine off and the key set to ON.
Page 62 Norge 1200 Electrical system Air temperature sensor - instrument panel Characteristic Resistance 10 kOhm (at 25°C - 77°F) Resistance 32.5 kOhm (at 0°C - 32°F) Dashboard PIN USE 1 + KEY 2 RIGHT TURN INDICATOR CONTROL 3 OIL PRESSURE SENSOR...
Page 63: Heated Handgrip Control
Norge 1200 Electrical system 25 HEATED HANDGRIP CONTROL 26 CAN L 27 CAN H 28 K LINE 29 - 30 AERIAL 1 31 - 32 - 33 - 34 RIGHT REAR TURN INDICATOR ACTIVA- TION 35 RIGHT FRONT TURN INDICATOR ACTIVA-...
Page 64 Norge 1200 Electrical system ELE SYS - 22...
Page 65: Index Of Topics
INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 66: Removing The Engine From The Vehicle
Norge 1200 Engine from vehicle Removing the engine from the vehicle • To remove the engine block, first re- move the air filter casing, the oil pan guard and disconnect the battery. • Remove the fork and the bevel gear pair.
Page 67 Norge 1200 Engine from vehicle • Disconnect the idle motor connector. • Disconnect the engine temperature sensor connector. • Disconnect the throttle valve position sensor connector. ENG VE - 3...
Page 68 Norge 1200 Engine from vehicle • Disconnect the revolution sensor con- nector. • Disconnect the alternator connector. • Disconnect the neutral sensor connec- tor. ENG VE - 4...
Page 69 Norge 1200 Engine from vehicle • Unscrew and remove the two screws. • Remove the starter motor protection. • Unscrew and remove the screw. • Disconnect the earth leads. • Disconnect the starter motor connec- tors. ENG VE - 5...
Page 70 Norge 1200 Engine from vehicle • Disconnect the Lambda probe connec- tor. • Place a container to collect the oil. • Open the clutch bleed pipe. • Drain clutch oil completely. • Unscrew and remove the screw fixing the oil clutch pipe and collect the wash- •...
Page 71 Norge 1200 Engine from vehicle • Unscrew and remove the radiator up- per fixing column. • Unscrew and remove the lower pin nut and collect the washer. • Remove the lower pin and collect the washer. • Remove the centre stand.
Page 72 Norge 1200 Engine from vehicle • Loosen the clamp. • Unscrew and remove the screws and collect the washers. • Remove the exhaust manifolds. • Remove the catalytic converter. ENG VE - 8...
Page 73 Norge 1200 Engine from vehicle • Place the engine service stand. • Operating from both sides, unscrew and remove the front fixing screw. • Remove the clamps from the cable harness. • Unscrew and remove the two screws fixing the oil vapour union tube.
Page 74 Norge 1200 Engine from vehicle • Partially lower the engine. • Disconnect the oil pressure sensor connector. • Lower the engine completely. Installing the engine to the vehicle • Fasten the vehicle chassis to a hoister and lift the engine to place it in its po- sition.
Page 75 Norge 1200 Engine from vehicle • Fit the oil vapour union tube. • Tighten the two screws. • Operating from both sides, tighten the front fixing screw. • Fit the catalytic converter. • Fit the exhaust manifolds. ENG VE - 11...
Page 76 Norge 1200 Engine from vehicle • Fit the washers and tighten the nuts. • Tighten the clamp. • Fit the centre stand. • Insert the lower pin and its washer. ENG VE - 12...
Page 77 Norge 1200 Engine from vehicle • Fit the washer and tighten the engine lower fixing nut to the specified torque. • Fit the oil radiator. • Screw the upper fixing column. • Connect the horn connectors. • Fasten the clutch oil pipe with the screw and its washers.
Page 78 Norge 1200 Engine from vehicle • Fit the clutch bleed pipe. • Fill up the clutch system. • Connect the Lambda probe connector. • Fit the starter motor connector. • Screw the nut and place the rubber cover. • Fit the earth leads.
Page 79 Norge 1200 Engine from vehicle • Tighten the screw. • Fit the starter motor protection. • Tighten the two screws. • Connect the neutral sensor connector. • Connect the alternator connectors. ENG VE - 15...
Page 80 Norge 1200 Engine from vehicle • Connect the revolution sensor connec- tor. • Connect the throttle valve position sen- sor connector. • Connect the engine temperature sen- sor connector. ENG VE - 16...
Page 81 Norge 1200 Engine from vehicle • Connect the idle motor connector. • Correctly fit the throttle cables, adjust- ing clearance. • Connect the injector connectors. ENG VE - 17...
Page 82 Norge 1200 Engine from vehicle • Connect the four spark plug tubes. • Refit the entire fork, reaction rod, con- necting rod assembly, brake calliper and the rear wheel. ENG VE - 18...
Page 83: Index Of Topics
INDEX OF TOPICS NGINE...
Page 84 Norge 1200 Engine Gearbox Diagram KEY: 1. Ball bearing 2. Circlip ENG - 2...
Page 85 Norge 1200 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 86 Norge 1200 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 87: Removing The Gearbox
Norge 1200 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 88: Gearbox Shafts
Norge 1200 Engine • Undo and remove the two screws. • Undo and remove the screw. • Remove the gearbox. See also Removing the starter motor Replacement Gearbox shafts ENG - 6...
Page 89 Norge 1200 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 90 Norge 1200 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 91 Norge 1200 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.
Page 92 Norge 1200 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 93 Norge 1200 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 - 11...
Page 94 Norge 1200 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 95 Norge 1200 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.
Page 96 Norge 1200 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 - 14...
Page 97 Norge 1200 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 98 Norge 1200 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...
Page 99 Norge 1200 Engine VEHICLES WITH CHASSIS NUMBER FROM ZGULPH0056M111111 TO ZGULPH0026M111194 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...
Page 100: Checking The Secondary Shaft
Norge 1200 Engine Checking the secondary shaft Measure the coaxiality of the transmission shaft with a dial gauge and a centring device and re- place it if not complying with specifications. Characteristic Shaft coaxiality limit 0.08 mm (0.0031 in) Check transmission gears for signs of pitting and wear and replace damaged gears if necessary.
Page 101: Assembling The Gearbox
Norge 1200 Engine • Check the transmission fork move- ment and if it is not regular, replace the transmission forks. See also Disassembling the gearbox Fitting the primary shaft NOTE TO REFIT, FOLLOW THE SAME INSTRUCTIONS AS FOR REMOVAL BUT IN REVERSE ORDER.
Page 102: Removing The Flywheel
Norge 1200 Engine Flywheel Removing the flywheel • Remove the clutch. • Place the locking tool on the flywheel and undo the six sealing screws of the flywheel, operating diagonally and in stages. • Remove the locking tool. Specific tooling 12.91.18.01 Tool to lock flywheel and start-up...
Page 103: Installing The Flywheel
Norge 1200 Engine Installing the flywheel • Position the flywheel. NOTE RESPECT THE FLYWHEEL POSITIONING REF- ERENCES. CAUTION THE SCREWS MUST BE REPLACED WITH NEW ONES AT THE FOLLOWING REFITTING AS THEY ARE SUBJECT TO HIGH LOADS AND STRESS. •...
Page 104 Norge 1200 Engine • Remove the cover. • Undo and remove the eight screws. • Undo and remove the two screws. • Unscrew the nut and collect the screw. ENG - 22...
Page 105 Norge 1200 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 - 23...
Page 106: Tensioning The Belt
Norge 1200 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.
Page 107: Installing The Generator
Norge 1200 Engine • Unscrew and remove the spacer. • Undo 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 05.94.86.30), tension the belt to the...
Page 108 Norge 1200 Engine • Replace the gasket and place the al- ternator frame using the front cover in- sertion cone. • Remove the insertion cone afterwards. Specific tooling 05.91.17.30 Front cover insertion cone • Tighten the two screws. • Tighten the eight lower screws.
Page 109 Norge 1200 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 05.94.86.30), tension the belt to the prescribed torque and screw the set screw.
Page 110: Removing The Starter Motor
Norge 1200 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 111: Disassembling The Clutch
Norge 1200 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 flywheel and start-up...
Page 112 Norge 1200 Engine Extract from the inside of the engine flywheel: • the clutch disc. • The intermediate plate. • The second clutch disc. • The pressure plate disc cover. ENG - 30...
Page 113: Checking The Clutch Plates
Norge 1200 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.
Page 114: Assembling The Clutch
Norge 1200 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 115 Norge 1200 Engine • Remove the locking tool. • Fit the clutch disc. Specific tooling 12.91.18.01 Tool to lock flywheel and start-up crown gear • The intermediate disc. • The clutch disc. • Place the crown gear aligning its refer- ence with that on the flywheel.
Page 116: Removing The Head Cover
Norge 1200 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 117: Removing The Cylinder Head
Norge 1200 Engine • Remove the head cover and collect the gasket. Removing the cylinder head • Remove the rocking arm rods. • Unscrew and remove the outer spark plug. • Loosen the nut and disconnect the pipes that deliver oil to the head.
Page 118 Norge 1200 Engine • Unscrew and remove the joint of the pipe that delivers oil to the head and collect the washer. • Using the suitable special tool, un- screw and remove the inner spark plug. Specific tooling 05.90.19.30 Inner spark plug removal •...
Page 119: Cylinder Head
Norge 1200 Engine • Slightly detach the cylinder head and remove the four O-rings. • Remove the head and collect the gas- ket. Cylinder head Removing the rocker arms NOTE THE FOLLOWING OPERATIONS REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH HEADS.
Page 120: Removing The Valves
Norge 1200 Engine • Remove the rocking lever shafts. • Remove the rocking levers and collect the three washers. See also Removing the head cover Removing the valves • Remove the head. • Place the special tool on the upper cap and at the centre of the head of the valve to be removed.
Page 121: Checking The Valve Guides
Norge 1200 Engine • Remove the upper retainer (2). • Remove the internal spring (3). • Remove the external spring (4). • Remove the lower retainer (5) and the shimming washers if necessary. • Remove the valve (6) from inside the head.
Page 122: Checking The Cylinder Head
Norge 1200 Engine VALVE AND GUIDES COUPLING DATA CHART (OUTLET) Specification Desc./Quantity Valve guide inside di- 8.005 ÷ 8.022 (0.3152 ÷ ameter mm (in) 0.3158) Valve stem diameter 7.965 ÷ 7.980 (0.3136 ÷ mm (in) 0.3142) Fitting clearance mm 0.025 ÷ 0.057 (0.0010 ÷...
Page 123 Norge 1200 Engine • Place the valve (6) inside the head. • Place the lower retainer (5) and the shimming washers. • Place the external spring (4). • Place the internal spring (3). • Insert the upper retainer (2). •...
Page 124 Norge 1200 Engine Installing the rocker arms CAUTION UPON REFITTING, ALWAYS REPLACE THE O- RINGS CAUTION UPON REFITTING, DO NOT INVERT THE PO- SITION OF THE ROCKING LEVER SUPPORTS SO AS NOT TO COMPROMISE LUBRICATION. • Install the rocking lever rods if they have been previously removed.
Page 125 Norge 1200 Engine • Place the six washers and install the rocking levers. • Insert the rocking lever shafts. • Rotate the crankshaft to TDC position in combustion phase (closed valves) for the left cylinder. • Tighten the two screws.
Page 126: Chain Removal
Norge 1200 Engine Chain removal • Remove the engine assembly. • Remove the alternator. • Clearly indicate the distribution timing marks that should be restored at the next refitting (left cylinder TDC). • Using the adequate tool, lock the igni- tion crown.
Page 127 Norge 1200 Engine • Unscrew and remove the central seal- ing nut of the timing system control gear on the crankshaft and collect the washer. • Unscrew and remove the oil pump gear nut and collect the washer. • Remove the chain tensioner and col- lect the spring.
Page 128 Norge 1200 Engine • Remove the rocking lever support. • Remove the two rocking lever rods See also Removing the rocker arms Removing the tappets • Remove the engine assembly. • Remove both heads. • Slide off and remove the tappets from their seat on both sides.
Page 129: Removing The Camshaft
Norge 1200 Engine Removing the phonic wheel • Remove the timing chain. • Slide off the tone wheel and collect the plug. See also Chain removal Removing the camshaft • Remove the timing chain. • Remove the tone wheel. •...
Page 130: Installing The Camshaft
Norge 1200 Engine • Remove the camshaft. See also Chain removal Removing the phonic wheel Removing the tappets Removing the rods 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 131: Installing The Chain
Norge 1200 Engine Installing the chain For the installation of the three gears and of the timing chain carry out the operations indicated in section "Timing". Cam timing • On the crankcase, fit the crankshaft and the camshaft. • Fit the cylinders and the heads.
Page 132 Norge 1200 Engine • Place the shim washer adequately so that the timing chain do not wear out the crankcase. • Fit the three timing system gears and the chain aligning the references on the camshaft and crankshaft gears. •...
Page 133 Norge 1200 Engine • Turn the oil pump shaft and introduce the gear pulling woodruff key. • Introduce the chain tensioner. • Remove the flywheel locking tool. • Check the crankshaft rotation. • Fit the rocking levers. Specific tooling 12.91.18.01 Tool to lock flywheel and start-up crown gear...
Page 134 Norge 1200 Engine • With a screw, fasten the specific arrow to the threaded hole to the left of the crankcase. Specific tooling 17.94.75.60 Arrow to control ignition timing • Fit the dial gauge support and then the gauge itself on the left outer spark plug hole.
Page 135 Norge 1200 Engine • Observing the timing system diagram, check timing considering that: A - intake start opens 22° before TDC B - outlet end closes 24° after TDC C - outlet start opens 52° before BDC D - intake end closes 54° after BDC •...
Page 136 Norge 1200 Engine • Refit the spark plugs and finish the refit. Specific tooling 981006 Graduated dial hub 19.92.96.00 Graduated dial to control ignition timing 17.94.75.60 Arrow to control ignition timing Measuring air gap • Undo and remove the two screws and remove the sensor.
Page 137: Removing The Cylinder
Norge 1200 Engine • 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 thick- ness gauge. Subtract the plain washer...
Page 138: Disassembling The Piston
Norge 1200 Engine • Slide off the cylinder from the stud bolts, paying attention not to damage the piston. See also Removing the cylinder head Disassembling the piston NOTE THE OPERATIONS DESCRIBED BELOW REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH HEADS.
Page 139: Fitting The Piston
Norge 1200 Engine • Mark the piston crown on the outlet side to remember its position when re- fitting. • Remove the piston. See also Removing the cylinder Fitting the piston NOTE THE OPERATIONS DESCRIBED BELOW REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH HEADS.
Page 140: Installing The Cylinder
Norge 1200 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 141: Installing The Cylinder Head
Norge 1200 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. •...
Page 142 Norge 1200 Engine • Using the suitable special tool, screw the inner spark plug. Specific tooling 05.90.19.30 Inner spark plug removal • Insert the washer and screw the joint of the pipe that delivers oil to the head . •...
Page 143 Norge 1200 Engine • Connect the pipes that deliver oil to the head and screw the nut. • Install the outer spark plug. • Replace the gasket and install the head cover. See also Installing the valves Installing the head cover Installing the head cover •...
Page 144: Crankcase - Crankshaft
Norge 1200 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 145 Norge 1200 Engine • Remove the crankshaft afterwards. See also Disassembling the connecting rod Disassembling the connecting rod • Remove the heads. • Remove the cylinders and the pistons. • Remove the clutch. • Remove the flywheel. • Remove the timing system.
Page 146: Checking The Connecting Rod
Norge 1200 Engine MAIN JOURNAL DIAMETER ON THE TIMING SYSTEM SIDE (A) Specification Desc./Quantity Main journal regular production 37.975 mm (1.49507 inch) 37.959 mm (1.49444 inch) 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 ÷...
Page 147 Norge 1200 Engine The maximum parallelism and plane error of the two shafts of the head and rod small end, measured at 200 mm (7.873 inch) should be +/- 0.10 mm (0.00393 inch). CONNECTING ROD BEARING THICKNESS Specification Desc./Quantity Connecting rod bearing regular (production) 1.535 - 1.544 mm (0.06043 - 0.06079 in)
Page 148: Installing The Crankshaft
Norge 1200 Engine Assembling the connecting rod • The references on the connecting rods should be facing the flywheel. • Do not interchange left and right con- necting rods. • Place the connecting rods and the caps (B) on the crankshaft and fasten them with new screws (A).
Page 149 Norge 1200 Engine • Introduce the crankshaft. • Place the flywheel side crankshaft sup- port flange, taking into account the fit- ting order indicated by the holes. Specific tooling 19.92.71.00 Tool to fit the sealing ring on the flywheel-side flange •...
Page 150 Norge 1200 Engine • Unscrew and remove the three screws fixing the oil pump. • Remove the oil pump. Installing • Place the oil pump. • Tighten the three screws fixing the oil pump. • Place the shim washer adequately so that the timing chain do not wear out the crankcase.
Page 151 Norge 1200 Engine • Pull out the oil filler plug / engine oil level dipstick. • 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.
Page 152 Norge 1200 Engine • Unscrew and remove the two screws. • Remove the mesh filter and collect the gasket. • Remove the black flange and collect the gasket. • Unscrew and remove the plug. • Remove the thermostatic valve. ENG - 70...
Page 153 Norge 1200 Engine • Unscrew and remove the pressure re- lief valve plug. • Remove the pressure relief valve com- ponents Refitting the oil sump • Place the pressure relief valve compo- nents correctly. • Screw the pressure relief valve plug.
Page 154 Norge 1200 Engine • In case of overpressure, the engine oil goes back into the oil sump through the hole indicated in the picture. • Place the thermostatic valve. CHECK THAT THE ENGINE OIL PASSAGE HOLE IS NOT CLOGGED. •...
Page 155 Norge 1200 Engine • 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. • Refit the oil sump on the base.
Page 156 Norge 1200 Engine • Remove the clamp. • Release the two straps retaining the oil breather pipe. • Remove the two oil breather pipes. • Unscrew and remove the oil return pipe positioning screw. • Release the oil return pipe...
Page 157 Norge 1200 Engine • Remove the complete blow-by system. ENG - 75...
Page 158 Norge 1200 Engine ENG - 76...
Page 159: Index Of Topics
INDEX OF TOPICS P SUPP OWER SUPPLY...
Page 160: Circuit Diagram
Norge 1200 Power supply Circuit diagram Key: 1. Fuel tank assembly 2. Fuel pipe 3. Throttle body 4. Joint 5. Three-way joint 6. Pipe Injection P SUPP - 2...
Page 161 Norge 1200 Power supply Diagram Key: 1. Control unit 2. Ignition switch 3. Battery 4. Fuel pump 5. Coils 6. Instrument panel 7. Air temperature sensor 8. Throttle valve position sensor 9. Injectors 10. Engine temperature sensor 11. Crankshaft position sensor 12.
Page 162 Norge 1200 Power supply 13. Side stand 14. Fall sensor Cylinders synchronisation • With engine off, connect the Axone 2000 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 163 Norge 1200 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 164: Recovery Function
Norge 1200 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 165 Norge 1200 Power supply Engine parameter reading screen page ENGINE PARAMETER READING This display shows the parameters measured by the several sensors (engine revs, engine temper- ature, etc.) or values set by the control unit (injec- tion time, ignition advance, etc.)
Page 166: Device Status
Norge 1200 Power supply Specification Desc./Quantity Steps set by the control unit for the Stepper motor. At idle, steps so that the engine keeps the target engine revs set by the control unit Stepper regulator Difference between current steps of motor at idle...
Page 167: Errors Display
Norge 1200 Power supply Specification Desc./Quantity Indicates if the control unit detects the revolution sensor signal correctly Devices activation screen page DEVICES ACTIVATION This displays is used to delete errors in the control unit memory and activate some systems control-...
Page 168 Norge 1200 Power supply Specification Desc./Quantity tomer. Careful with the air pressure sensor in the instrument panel Air temperature Possible short circuit in the earth lead, battery or open circuit: recovery function hardly noticeable for customer. Engine temperature Possible short circuit in the earth lead, battery or open circuit: recovery function.
Page 169: Adjustable Parameters
Norge 1200 Power supply Adjustable parameters screen page ADJUSTABLE PARAMETERS This screen page is used to adjust some control unit parameters ADJUSTABLE PARAMETERS Specification Desc./Quantity Throttle positioner autodetection Allows the control unit to detect the closed throttle position: just press the enter button...
Page 170 Norge 1200 Power supply P SUPP - 12...
Page 171 INDEX OF TOPICS SUSP USPENSIONS...
Page 172 Norge 1200 Suspensions Front Front fork Diagram KEY: 1. Screw 2. Right sleeve 3. Left sleeve 4. Upper bushing 5. Cap 6. Sealing ring 7. Locking ring 8. Dust guard 9. Buffer 10. Washer 11. Screw 12. Pin 13. Complete cover 14.
Page 173: Removing The Fork Legs
Norge 1200 Suspensions 15. Complete pumping member 16. Ring 17. Lower bushing 18. Stem 19. Preload tube 20. Spring 21. Locking ring 22. Bushing 23. Nut 24. Fifth wheel 25. O-Ring 26. Cap body 27. O-Ring 28. Rigging pin Removing the fork legs •...
Page 174 Norge 1200 Suspensions • Undo 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 175 Norge 1200 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. • Support the fork stem and loosen the screws on the upper and then the lower plate.
Page 176: Draining Oil
Norge 1200 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 177: Disassembling The Fork
Norge 1200 Suspensions • Press the stem inside the wheel holder sleeve. • Remove the spring. • Drain out all the oil inside the stem. • Collect the preload tube. NOTE FOR EASY DRAINAGE OF THE OIL INSIDE THE PUMPING MEMBER ROD, PRESS THE STEM IN THE WHEEL HOLDER SLEEVE TO PUMP OIL OUT.
Page 178 Norge 1200 Suspensions • Remove the dust scraper using a screwdriver as a lever. CAUTION BE CAREFUL NOT TO DAMAGE THE SLEEVE RIM AND THE DUST SCRAPER. • Remove the locking ring inside the sleeve using a thin screwdriver. CAUTION BE CAREFUL NOT TO DAMAGE THE SLEEVE RIM.
Page 179: Checking The Components
Norge 1200 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 180 Norge 1200 Suspensions Sleeve 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; • pumping member.
Page 181 Norge 1200 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 counter spring and ring.
Page 182 Norge 1200 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 183: Filling Oil
Norge 1200 Suspensions • Fit the dust scraper. Filling oil • Place the sleeve upright in a vice fitted with protection shoes. • Compress the sleeve in the stem. • Pour part of the fork oil into the sleeve. •...
Page 184 Norge 1200 Suspensions • Insert the preload tube and the spring. • Place the cap on the bearing tube, tak- ing care not to damage the O-ring. • Then, tighten the cap to the prescribed torque. SUSP - 14...
Page 185: Installing The Fork Legs
Norge 1200 Suspensions Installing the fork legs • Insert the fork stem in position. • Insert the wheel pin so that the stems are aligned. • Tighten the screws on the fork plates to the prescribed torque. SUSP - 15...
Page 186 Norge 1200 Suspensions • Remove the wheel pin • Place the right side wheel with spacer. • Insert the pin. • Tighten the terminal screws (nut side) to lock the wheel pin • Insert the sealing washer on the wheel pin.
Page 187: Steering Bearing
Norge 1200 Suspensions • Fit the brake callipers tightening the fix- ing screws to the prescribed torque. CAUTION AFTER FITTING THE BRAKE CALLIPERS, OP- ERATE THE FRONT BRAKE LEVER SEVERAL TIMES • Fit the speed sensor. • Tighten the speed sensor screw.
Page 188 Norge 1200 Suspensions • Operating on both half-handlebars, re- move the lower fastening screw to the fork plate. • Operating on both half-handlebars, re- move the two upper fastening screws to the fork plate. • Remove both half-handlebars but keep them connected to the cables.
Page 189 Norge 1200 Suspensions • Remove the upper screw fastening the light holder fitting. • Operating from both sides, remove the screw fastening the light holder fitting to the lower fork plate. • Operating from both sides, remove the screw fixing the fork stems to the upper plate.
Page 190 Norge 1200 Suspensions • Slide off the fork upper plate moving it towards the instrument panel. • Rivet the safety washer on the head- stock. CAUTION UPON REFITTING REPLACE THE SAFETY WASHER WITH A NEW ONE. • Unscrew the upper ring nut.
Page 191 Norge 1200 Suspensions • Adjust the preloading of the steering bearings with the special tool. NOTE GET THE ADEQUATE SPECIAL TOOL. Specific tooling AP8140190 Tool for steering tightening SUSP - 21...
Page 192 Norge 1200 Suspensions SUSP - 22...
Page 193: Index Of Topics
INDEX OF TOPICS CHAS HASSIS...
Page 194: Swinging Arm
Norge 1200 Chassis Swinging arm Removing • To remove the fork, first remove both footrest supporting plates and the ex- haust silencer. • Slide off the rear brake calliper from the disc and release the brake pipe. • Release the cable harness from the clamps and remove the speed sensor.
Page 195 Norge 1200 Chassis • Remove the clamp from the dust guard cap. • Loosen the two fork terminal screws. • Loosen the ring nut. Specific tooling 05.91.26.30 Tool for tightening the fork pin ring nut - clutch hub • Helped by a second operator, remove the pin and remove the fork with cardan shaft.
Page 196 Norge 1200 Chassis Checking • Check that the universal joint is not damaged, the gear teeth inserting in the sleeve grooves and the grooves on the joint are not deformed or damaged; otherwise, replace the joint. • Check that the rubber bellows are not cut or pierced; otherwise, replace it.
Page 197 Norge 1200 Chassis • Use the suitable box-spanner to tight- en the ring nut. Specific tooling 05.91.26.30 Tool for tightening the fork pin ring nut - clutch hub • Tighten the two fork terminal screws. • Fit the dust guard cap in the gearbox.
Page 198 Norge 1200 Chassis • Place the connecting rod assembly on the fork. • Insert the screw. • Tighten the fixing nut of the connecting rod assembly. • Place the dust-protection ring between the rim and the cardan shaft taking care to mount it with the collar facing the transmission unit.
Page 199 Norge 1200 Chassis • Unscrew and remove the nut fixing the reaction rod. • Remove the screw. • Fasten the reaction rod to the chassis with a clamp. • Undo and remove the four screws. • Remove the transmission casing slid- ing off the universal joint.
Page 200 Norge 1200 Chassis REMOVAL Remove the bushing (1) with a punch. Turn the support (5) over and remove the other bushing (8). Remove the sealing rings (2) and (7) with a screw- driver. Remove the stop rings (3) and (6) from the support (5) with suitable pliers.
Page 201 Norge 1200 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 202 Norge 1200 Chassis Manually assemble the new sealing rings (2) and (7). Assemble the bushing (1). Drive the bushing (1) in with a plastic hammer. Turn the support (5) over and assemble the other bushing (8). Pinion unit REMOVAL Remove the stop ring (1) from the ring nut.
Page 203 Norge 1200 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 204 Norge 1200 Chassis Tighten the ring nut (2) with the special spanner (s4) to the prescribe torque. Insert the stop ring (1) in the ring nut (2) in the in- dicated direction. Assembly position of the stop ring (1). CAUTION MAKE SURE THE STOP RING IS IN ITS SEAT.
Page 205 Norge 1200 Chassis REMOVAL Remove the bearing from the wheel axle with a suitable extractor. Turn the unit over. Remove the bearing from the wheel axle with a suitable extractor. FITTING Heat the bearings to 100°C (212 °F). Assemble the bearings to the wheel axle.
Page 206 Norge 1200 Chassis Turn the unit over. Assemble the bearings to the wheel axle. Casing unit fitting Assemble the dowel pins to the casing with the buffer and a hammer. Assemble the casing to the special fastening tool. Clean the casing faying surfaces carefully.
Page 207 Norge 1200 Chassis Insert the support group in the casing. Assemble the cap and the ring. Fit the cap on the support. Fit the clamp. Screw the clamp with the specific pliers. CHAS - 15...
Page 208 Norge 1200 Chassis Apply the prescribed sealant to the casing. Fit a new sealing ring using the buffer. Lubricate the sealing ring. Assemble two centring stud bolts with M8 thread in the threaded holes of the casing as shown in the picture.
Page 209 Norge 1200 Chassis Assemble the fixing screws (7). Tighten the screws (7) to the prescribed torque. Remove excessive sealant. Assemble the ring to the casing. Tighten the fixing screws to the prescribed torque. Fit the cap with the washer. Screw the cap to the prescribed torque.
Page 210 Norge 1200 Chassis Fit the breather with the washer. Screw the breather to the prescribed torque. Fill the transmission with the prescribed oil. Fit the cap with the washer. Screw the cap to the prescribed torque. Assemble the cap with the clamps.
Page 211 Norge 1200 Chassis Remove the cover (20). Remove the plug (3) to drain out the oil. Lift the cap (10). CHAS - 19...
Page 212 Norge 1200 Chassis Remove the clamps (9) and (11). Remove the cap (14). Remove the screws (16). Collect the ring (15). Remove the screws (7). Remove the casing (4). CHAS - 20...
Page 213: Troubleshooting
Norge 1200 Chassis Remove the clamp (12). Remove the cap (14). Collect the ring (13). Remove the support unit (8). TROUBLESHOOTING Possible Cause Operation 1. Fitting error of the radial seal or seal damaged 1. Replace the sealing ring and fit it correctly with 2.
Page 214 Norge 1200 Chassis Possible Cause Operation 1. Casing not sealed 2. Closing screws of the cas- 1. Open the casing shells, clean the surfaces, seal ing shells not tightened to the prescribed torque. it and reassemble the casing 2. Tighten the closing screws to the correct torque 1.
Page 215 Norge 1200 Chassis • Place the reaction rod into its seat. • Insert the screw. • Screw the nut fixing the reaction rod. • Place the dust-protection ring between the rim and the cardan shaft taking care to mount it with the collar facing the transmission unit.
Page 216 Norge 1200 Chassis • Release and remove the spring be- tween the exhaust end and the cata- lytic converter. • Loosen the clamp between the ex- haust end and the catalytic converter. • Unscrew and remove the silencer fix- ing nut and collect the screw and the bushing.
Page 217: Removing The Exhaust Manifold
Norge 1200 Chassis Removing the lambda sensor Removing the exhaust manifold The engine and the exhaust system components get very hot and remain in this condition for a certain time interval after the engine has been shut off. Before handling these components, make sure that you are wearing insulating gloves or wait until the engine and the exhaust system have cooled down.
Page 218 Norge 1200 Chassis CHAS - 26...
Page 219: Index Of Topics
INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 220 Norge 1200 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 221: Operating Diagram
Norge 1200 Braking system Operating diagram 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 with a traditional 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 222 Norge 1200 Braking system At engine start-up, the ABS warning light (7) lights up 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 malfunc- tion has been detected and the ABS has been deactivated.
Page 223 Norge 1200 Braking system 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 4) Front brake calliper...
Page 224: Abs Operation
Norge 1200 Braking system 17) Rear inlet valve ABS OPERATION General specifications: • The front and rear circuits are similar. • The ABS inlet valve (16 - 17) is usually open and it is closed only when the system intervenes to avoid wheel locking.
Page 225 Norge 1200 Braking system ISO screen page This display shows general data regarding the control unit, for example software type, mapping, control unit programming date ISO DISPLAY Specification Desc./Quantity ISO Code C1EF Manufacturer serial number 540ABS01 Server algorithm sw codes...
Page 226 Norge 1200 Braking system Device status screen page DEVICE STATUS This screen page shows the status (ON/OFF only) of the vehicle devices or the operation condition of some vehicle systems (for example, lambda probe functioning status) DEVICE STATUS Specification Desc./Quantity...
Page 227 Norge 1200 Braking system Errors display screen page ERRORS DISPLAY This screen page shows potential errors detected in the vehicle (ATT) or stored in the control unit (MEM) and it is possible to check error deletion (STO) ERRORS DISPLAY Specification Desc./Quantity...
Page 228 Norge 1200 Braking system panel, it means that the CAN line is operating correctly and that the instrument panel speed indication does not work due to the instrument panel. In case of ABS warning light turns on and the ABS control deactivates, check whether: Axone com- municates with the ABS module or Axone detects one or more errors.
Page 229 Norge 1200 Braking system Checks: check the speed sensor signal (0.5 or 1 V) on the brown cable between pin 1 of the rear speed sensor connector and pin 19 of the ABS module connector. If there is not enough voltage, check cable continuity from the ABS module to the speed sensor connector and make sure that the cable is earthed insulated.
Page 230 Norge 1200 Braking system Description of the defect: the control unit detects a failure in the ABS valves relay or lack of power supply in pin 3 of the control unit. Checks: check pin 3 of the ABS control unit connector, the 25 A fuse continuity and the relative wiring (red/white).
Page 231: Component Maintenance
Norge 1200 Braking system • Unscrew and remove the two nuts (3) and collect the two washers. • Remove the ABS control unit from the vehicle. CAUTION DO NOT OPEN THE ABS CONTROL UNIT: IN CASE OF MALFUNCTION REPLACE THE WHOLE UNIT.
Page 232: Front Brake Pads
Norge 1200 Braking system IF A VALUE BEYOND THE TOLERANCE RANGE IS MEASURED, REPLACE THE SEN- SOR (1) AND/OR THE TONE WHEEL (2) AND REPEAT THE CHECKS; MAKE SURE THAT THE VALUES ARE WITHIN THE TOLERANCE LIMITS. TONE WHEELS (2) CLEANING It is important to check that all the tone wheels (2) are always clean.
Page 233: Rear Brake Pads
Norge 1200 Braking system • Remove both pins. • Remove the vibration-damping plate. • Extract one pad at a time. CAUTION AFTER REMOVING THE PADS, DO NOT OP- ERATE THE BRAKE CONTROL LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS.
Page 234 Norge 1200 Braking system • Remove the pin. • Extract one pad at a time. CAUTION AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE CONTROL LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS.
Page 235 Norge 1200 Braking system Front If there is air in the hydraulic system, it acts as a bearing, absorbing a large part of the pressure from the brake pump and minimising calliper effi- ciency during braking. The presence of air is signalled by the "spongi- ness"...
Page 236 Norge 1200 Braking system • 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. NOTE WHILE PURGING THE HYDRAULIC SYSTEM, FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID.
Page 237 Norge 1200 Braking system the brake lever and will make it reach the end of stroke. • Close the bleed valve before the lever reaches its end of stroke. • Repeat the operation until the fluid draining into the container is air-bubble free.
Page 238 Norge 1200 Braking system BRAK SYS - 20...
Page 239 INDEX OF TOPICS BODYW ODYWORK...
Page 240: Headlight Fairing
Norge 1200 Bodywork Headlight fairing • Remove the instruments cover. • Operating from both sides, unscrew and remove the three internal screws. • Unscrew and remove the two front screws. • Move the windshield forward. • Disconnect the front head lamp con- nectors .
Page 241 Norge 1200 Bodywork • Remove the oil breather pipe. • Undo and remove the two screws from the oil vapour recovery reservoir. • Unscrew and remove the tube guide screw on the air filter casing. • Move the oil vapour recovery reservoir aside.
Page 242 Norge 1200 Bodywork • Operating from both sides, loosen the clamp and slide off the sleeve from the throttle body. • Lift the air filter casing and slide off the fuel depression pipe. • Remove the air filter casing. Fuel tank •...
Page 243 Norge 1200 Bodywork • Operating from both sides, unscrew and remove the two front screws. • Unscrew and remove the rear screw. • Lift the fuel tank and remove the pipes from the union tee. • Disconnect the connector. BODYW - 5...
Page 244 Norge 1200 Bodywork • Disconnect the fuel pipe. • Remove the fuel tank by sliding it off and back. Instrument cluster cover • Remove the windshield. • Unscrew and remove both screws. • Remove the front shell. Locking torques (N*m) M5 Allen screws fixing the instrument panel and fairings 3.8 Nm...
Page 245 Norge 1200 Bodywork • Operating from both sides, unscrew and remove the two screws. Locking torques (N*m) M5 Allen screws fixing the instrument panel and fairings 3.8 Nm • Operating from both sides, release the instrument panel cover from the at- tachments on the windshield.
Page 246 Norge 1200 Bodywork Windscreen • Unscrew and remove the four screws. • Collect the four bushings. • Remove the windshield glass. Adjustable windscreen ELECTRICALLY ADJUSTABLE WINDSHIELD BODYW - 8...
Page 247 Norge 1200 Bodywork Key: 1. Complete electric motor 2. Riding block 3. TE flanged screw 4. Sliding block 5. Plate 6. TCEI screw BODYW - 9...
Page 248 Norge 1200 Bodywork 7. Knurled washer 8. Rubber ring 9. T-shaped bushing 10. Right support 11. Left support 12. Connecting rod 13. TBEI screw 14. Bushing 15. Spacer 16. Blind nut 17. Spacer 18. Bushing 19. Spacer 20. Washer 21. TCEI screw 22.
Page 249 Norge 1200 Bodywork • Disconnect the electric windshield mo- tor connector. • Remove the electric windshield motor. ELECTRIC WINDSHIELD ASSEMBLING IN- STRUCTIONS • Assemble the eight bushings (14) on the external side of the connecting rods (12). • Position the pin (12) on the movable support.
Page 250 Norge 1200 Bodywork • Fit the spacer (19) on the plate (5). • Insert the screw (21) and the washer (20) inside the plate (5). • Fit the spacer (17) on the screw (21). • Position the movable support (11).
Page 251 Norge 1200 Bodywork • Tighten the four screws (3d). • Tighten the four screws (3a). • Tighten the two screws (3b). Afterwards tighten and lock the two screws (6). BODYW - 13...

MOTO GUZZI Norge 1200 Service Manual

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