MOTO GUZZI Griso1200 8V Guide

SERVICE STATION MANUAL
854378
GRISO 8V - 1200

SERVICE STATION
MANUAL
GRISO 8V - 1200
THE VALUE OF SERVICE
Only the mechanics of the Official Moto Guzzi Service Network know this vehicle well, thanks to constant
technical professional development and Moto Guzzi specific training programmes, and have the tools
needed to carry out maintenance and repair operations correctly.
The reliability of the vehicle also depends on its mechanical conditions. Checking the vehicle before
setting off, carrying out routine maintenance and using only Moto Guzzi Original Spare parts is
fundamental!
For information about the nearest Official Dealer and/or Service Centre, consult the Yellow Pages or
search directly on the inset map in our Official Website:
www.motoguzzi.it
Only by purchasing Moto Guzzi Original Spare Parts will you get a product designed and tested during
the bike designing phase. Moto Guzzi Original Spare Parts are subject to systematic quality control
procedures so that their reliability and performance over time is guaranteed.
The descriptions and illustrations given in this publication are not binding; While the basic features as
described and illustrated in this booklet remain unchanged, Moto Guzzi reserves the right, at any time
and without being required to update this publication beforehand, to make any changes to components,
parts or accessory supplies, which it deems necessary to improve the product or which are required for
manufacturing or commercial reasons.
Not all versions shown in this publication are available in all Countries. The availability of individual
versions should be checked with the Official Moto Guzzi sales network.
© Copyright 2007- Moto Guzzi. All rights reserved. Reproduction of this publication in whole or in part is
prohibited. Moto Guzzi - After sales service.
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SERVICE STATION MANUAL
GRISO 8V - 1200
This manual provides the main information to carry out regular maintenance operations on your vehicle.
This manual is intended to Moto Guzzi Dealers and their qualified mechanics; several concepts have
been deliberately omitted as they are considered unnecessary. As it is not possible to include complete
mechanical notions in this manual, users should have basic mechanical knowledge or minimum
knowledge about the procedures involved when repairing scooters. Without this knowledge, repairing or
checking the vehicle may be inefficient or even dangerous. As the vehicle repair and check procedures
are not described in detail, be extremely cautious so as not to damage components or injure individuals.
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. These changes will be introduced in the subsequent editions of the manual. In case of
need or further queries on repair and check procedures, consult Moto Guzzi CUSTOMER
DEPARTMENT, which will be prepared to provide any information on the subject and any further
communications on updates and technical changes related to the vehicle.
NOTE Provides key information to make the procedure easier to understand and carry out.
CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.
Personal safety Failure to completely observe these instructions will result in serious risk of personal
injury.
Safeguarding the environment Sectionsmarkedwiththis symbol indicate the correct use of the vehicle
to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious
damage to the vehicle and sometimes even the invalidity of the guarantee.
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INDEX OF TOPICS
CHARACTERISTICS CHAR
SPECIAL TOOLS S-TOOLS
MAINTENANCE MAIN
ELECTRICAL SYSTEM ELE SYS
ENGINE FROM VEHICLE ENG VE
ENGINE ENG
POWER SUPPLY P SUPP
SUSPENSIONS SUSP
CHASSIS CHAS
BRAKING SYSTEM BRAK SYS
CLUTCH SYSTEM CLU SYS
BODYWORK BODYW
PRE-DELIVERY PRE DE
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INDEX OF TOPICS
CHARACTERISTICS CHAR
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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.
CAUTION
EXHAUSTEMISSIONSCONTAINCARBONMONOXIDE,APOISONOUSGASWHICHCANCAUSE
LOSS OF CONSCIOUSNESS AND EVEN DEATH.
Fuel
CAUTION
FUEL USED TO POWER INTERNAL COMBUSTION ENGINES IS HIGHLY FLAMMABLE AND CAN
BECOME EXPLOSIVE UNDER SPECIFIC CONDITIONS. IT IS THEREFORE RECOMMENDED TO
CARRY OUT REFUELLING AND MAINTENANCE PROCEDURES IN A VENTILATED AREA WITH
THE ENGINE SHUT OFF. DO NOT SMOKE DURING REFUELLING AND NEAR FUEL VAPOURS,
AVOID ANY CONTACT WITH NAKED FLAMES, SPARKS OR OTHER SOURCES WHICH MAY
CAUSE THEM TO IGNITE OR EXPLODE.
DO NOT DISPOSE OF FUEL INTO THE ENVIRONMENT.
KEEP OUT OF THE REACH OF CHILDREN
Hot components
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.
Used engine oil and transmission oil
CAUTION
IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN SERVICING THE VEHICLE.
ENGINE OR TRANSMISSION OIL MAY CAUSE SERIOUS INJURIES TO THE SKIN IF HANDLED
FOR PROLONGED PERIODS OF TIME AND ON A REGULAR BASIS.
WASH YOUR HANDS CAREFULLY AFTER HANDLING OIL.
HAND THE OIL OVER TO OR HAVE IT COLLECTED BY THE NEAREST USED OIL RECYCLING
COMPANY OR THE SUPPLIER.
DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT
KEEP OUT OF THE REACH OF CHILDREN
Brake and clutch fluid
GRISO 8V - 1200 Characteristics
CHAR - 7
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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.
KEEP OUT OF THE REACH OF CHILDREN
Battery electrolyte and hydrogen gas
CAUTION
BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND AS IT CONTAINS SULPHURIC ACID, IT
CAN CAUSE BURNS WHEN IN CONTACT WITH THE SKIN. WHEN HANDLING BATTERY ELEC-
TROLYTE, WEAR TIGHT-FITTING GLOVES AND PROTECTIVE APPAREL. IF THE ELECTRO-
LYTIC FLUID COMES INTO CONTACT WITH THE SKIN, RINSE WELL WITH ABUNDANT FRESH
WATER. IT IS PARTICULARLY IMPORTANT TO PROTECT YOUR EYES AS EVEN TINY
AMOUNTS OF BATTERY ACID MAY CAUSE BLINDNESS. IF THE FLUID GETS INTO CONTACT
WITH YOUR EYES, WASH WITH ABUNDANT WATER FOR FIFTEEN MINUTES AND CONSULT
AN EYE SPECIALIST IMMEDIATELY. IF THE FLUID IS ACCIDENTALLY SWALLOWED, DRINK
LARGE QUANTITIES OF WATER OR MILK, FOLLOWED BY MILK OF MAGNESIA OR VEGETA-
BLE OIL AND SEEK MEDICAL ADVICE IMMEDIATELY. THE BATTERY RELEASES EXPLOSIVE
GASES; KEEP IT AWAY FROM FLAMES, SPARKS, CIGARETTES OR ANY OTHER HEAT
SOURCE. ENSURE ADEQUATE VENTILATION WHEN SERVICING OR RECHARGING THE BAT-
TERY.
KEEP OUT OF THE REACH OF CHILDREN
BATTERY LIQUID IS CORROSIVE. DO NOT POUR OR SPILL IT, PARTICULARLY ON PLASTIC
COMPONENTS. ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BAT-
TERY TO BE ACTIVATED.
Maintenance rules
GENERAL PRECAUTIONS AND INFORMATION
When repairing, dismantling and reassembling the vehicle follow the recommendations reported below
carefully.
BEFORE DISASSEMBLING COMPONENTS
•Beforedismantling components, remove dirt, mud, dust and foreign bodies from the vehicle.
Use the special tools designed for this bike, as required.
COMPONENTS REMOVAL
•Do not loosen and/or tighten screws and nuts using pliers or other tools other than the
especially designed wrench.
•Mark positions on all connection joints (pipes, cables, etc.) before separating them, and
identify them with distinctive symbols.
•Each component needs to be clearly marked in order to be identified during assembly.
•Clean and wash the removed components carefully using a low-flammability detergent.
Characteristics GRISO 8V - 1200
CHAR - 8
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•Keep coupled parts together since they have "adjusted" to each other due to normal wear
and tear.
•Some components must be used together or replaced altogether.
•Keep away from heat sources.
REASSEMBLING COMPONENTS
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.
•When tightening nuts and screws, start from the ones with the largest section or from the
internal ones, moving diagonally. Tighten nuts and screws in successive steps before ap-
plying the tightening torque.
•Always replace self-locking nuts, washers, sealing rings, circlips, O-rings, split pins and
screws with new ones if their tread is damaged.
•When fitting bearings, make sure to lubricate them well.
•Check that each component is fitted correctly.
•After a repair or routine maintenance procedure, carry out pre-ride checks and test the ve-
hicle on private grounds or in an area with low traffic density.
•Clean all junction surfaces, oil guard rims and washers before refitting them. Smear a light
layer of lithium-based grease on the oil guard rims. Reassemble the oil guard and the bear-
ings with the brand or lot number facing outward (visible side).
ELECTRIC CONNECTORS
Electric connectors must be disconnected as described below as non-compliance with the procedure
so described causes irreparable damage to both the connector and the cable harness:
Press the relevant safety hooks, if any.
•Grip the two connectors and disconnect them by pulling them in opposite directions.
•Ifthereare signs of dirt, rust, humidity, etc.,cleantheconnector internal parts carefully using
a pressurised air jet.
•Make sure that the cables are correctly linked to the connector internal terminal ends.
•Then insert the two connectors making sure that they couple correctly (if the relevant hooks
are provided, you will hear them "click" into place).
CAUTION
TO DISCONNECT THE TWO CONNECTORS, DO NOT PULL THE CABLES.
NOTE
THE TWO CONNECTORS CONNECT ONLY FROM ONE SIDE: CONNECT THEM THE RIGHT WAY
ROUND.
TIGHTENING TORQUE
CAUTION
GRISO 8V - 1200 Characteristics
CHAR - 9
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DO NOT FORGET THAT THE TIGHTENING TORQUE OF ALL FASTENING ELEMENTS ON
WHEELS, BRAKES, WHEEL SPINDLES AND OTHER SUSPENSION COMPONENTS PLAY A KEY
ROLE IN ENSURING THE VEHICLE'S SAFETY AND MUST COMPLY WITH SPECIFIED VALUES.
CHECK THE TIGHTENING TORQUE OF FASTENING PARTS ON A REGULAR BASIS AND AL-
WAYS USE A TORQUE WRENCH TO REASSEMBLE THESE COMPONENTS. FAILURE TO COM-
PLY WITH THESE RECOMMENDATIONS MAY CAUSE ONE OF THESE COMPONENTS TO GET
LOOSE AND EVEN DETACHED, THUS BLOCKING A WHEEL, OR OTHERWISE COMPROMISE
VEHICLE HANDLING. THIS CAN LEAD TO FALLS, WITH THE RISK OF SERIOUS INJURY OR
DEATH.
Running-in
Engine run-in is essential to ensure engine long life and correct operation. Twisty roads and gradients
are ideal to run in engine, brakes and suspensions effectively. Vary your driving speed during run-in.
In this way, you allow for the work of components to be "loaded" and then "unloaded", thus cooling
engine parts.
CAUTION
THE CLUTCH MAY EMIT A SLIGHT BURNING SMELL WHEN FIRST USED. THIS PHENOMENON
SHOULD BE CONSIDERED NORMAL AND WILL DISAPPEAR AS SOON AS THE CLUTCH
PLATES GET ADAPTED.
ITISIMPORTANTTOSTRAIN ENGINE COMPONENTS DURINGRUN-IN,HOWEVER,MAKESURE
NOT TO OVERDO THIS.
CAUTION
ONLY AFTER THE SERVICE AT THE END OF THE RUN-IN PERIOD CAN THE BEST PERFORM-
ANCE OF YOUR VEHICLE BE OBTAINED.
Follow the guidelines detailed below:
•Do not twist the throttle grip abruptly and completely when the engine is working at a low
revs, either during or after run-in.
•During the first 100 km (62 miles) operate the brakes with caution, avoid rough and long
braking. 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.
Vehicle identification
SERIAL NUMBER POSITION
These numbers are necessary for vehicle registration.
NOTE
ALTERING IDENTIFICATION NUMBERS CAN BE SERIOUSLY PUNISHED BY LAW, PARTICU-
LARLY MODIFYING THE CHASSIS NUMBER WILL IMMEDIATELY INVALIDATE THE WARRAN-
TY.
Characteristics GRISO 8V - 1200
CHAR - 10
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This number is composed by numbers and letters,
as in the example shown below.
ZGULSE000YMXXXXXX
KEY:
ZGU: WMI (World manufacturer identifier) code;
LS: model;
E00: version variation;
0: digit free
Yyear of manufacture
M: production plant (M= Mandello del Lario);
XXXXXX: progressive number (6 digits);
CHASSIS NUMBER
The chassis number is stamped on the right side
of the headstock.
ENGINE NUMBER
The engine number is stamped on the left side,
close to the engine oil level check cap.
Dimensions and mass
WEIGHT AND DIMENSIONS
Specification Desc./Quantity
Length 2260 mm (89.0 in)
Max. width 830 mm (32.68 in)
Maximum height 1070 mm (42.1 in)
Saddle height 800 mm (31.5 in)
Minimum ground clearance 185 mm (7.3 in)
Wheelbase 1554 mm (61.2 in)
Kerb weight 240 kg (529 lb)
Engine
ENGINE
Specification Desc./Quantity
Type 90° transversal V-twin, four stroke
Cylinder quantity 2
Cylinder layout 90° V
Bore / stroke 95 x 81.2 mm (3.74 x 3.20 in)
Cubic capacity 1151 cm³ (70 cu.in.)
GRISO 8V - 1200 Characteristics
CHAR - 11
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Specification Desc./Quantity
Compression ratio 11: 1
Start-up electric
Engine revs at idle speed 1100 ± 100 rpm
Clutch dry single disc with integrated hydraulic drive and anti-vibration
buffer
Lubrication system Pressure-fed lubrication system adjusted through valves and a
trochoidal pump
Air filter cartridge, dry
Cooling air and oil with independent trochoidal pump and pressure reg-
ulating valve for the oil cooling system
Timing system diagram Single overhead camshaft with valves, bowls and rocking lev-
ers
Valid values with checking clearance between rocking levers
and valve inlet: 0.10 mm (0.0039 in) outlet: 0.15 mm (0.0059 in)
Transmission
TRANSMISSION
Specification Desc./Quantity
Main transmission With helical teeth, ratio 26/35 = 1:1.346
Gearbox Mechanical, 6 speeds with foot lever on the left hand side of
the engine
1st gear ratios 17/38 = 1 :2.2353
2nd gear ratios 20/34 = 1:1.7
3rd gear ratios 23/31 = 1:1.3478
4th gear ratios 26/29 = 1:1.1154
5th gear ratios 31/30 = 1:0.9677
6th gear ratios 29/25 = 1:0.8621
Final drive cardan shaft
Ratio 12/44 = 1:3.6667
Capacities
CAPACITY
Specification Desc./Quantity
Engine oil Oil change and oil filter replacement: 3,500 cm³ (214 cu.in)
Gearbox oil 500 cm³ (30.5 cu in)
Transmission oil 380 cm³ (23.2 cu in)
Fuel (reserve included) 16.4 l (4.33 Uk gal)
Fuel reserve 3.3 l (0.87 gal)
Fork oil 520 ± 2.5 cm³ (31.7 ± 0.15 in) (for each stem)
Seats 2
Vehicle maximum load 210 kg (463 lb) (rider + passenger + luggage)
Electrical system
ELECTRICAL SYSTEM
Specification Desc./Quantity
Spark plug NGK PMR8B (long life)
Electrode gap 0.6 - 0.7 mm (0.024 - 0.028 in)
Battery 12 V - 18 Ampere/hour
(Permanent magnet) Generator 12V - 550W
Main fuses 30 A
Auxiliary fuses 3 A - 15 A
Tail light 12V - 5 W
Low-/ High-beam light bulb (halogen) 12 V - 55 W/ 60 W H4
Turn indicators 12V - 10 W
Rear tail light / stop light LED
Characteristics GRISO 8V - 1200
CHAR - 12
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Specification Desc./Quantity
Instrument panel lighting LED
License plate light 12V - 5 W
Turn indicator warning light LED
Gear in neutral warning light LED
Alarm warning light - Gear shift LED
Side stand down warning light LED
Low fuel warning light LED
High-beam warning light LED
Oil pressure warning light LED
Frame and suspensions
CHASSIS
Specification Desc./Quantity
Type double cradle, high strength steel tube chassis
Trail 108 mm (4.25 in)
Headstock angle 26° 30'
Front Hydraulic telescopic upside-down fork, Ø 43 mm (1.69 in), with
foot for radially-mounted brake calliper, adjustable spring pre-
loading, hydraulic compression and rebound damping.
Wheel travel 120 mm (4.72 in)
Rear single-sided arm suspension with progressive rising-rate link-
age, single shock absorber with fully adjustable compression
and rebound damping and spring preloading.
Wheel travel 110 mm (4.33 in)
SIZES A AND B
Specification Desc./Quantity
Size A 793.4 mm (31.24 in)
Size B 344.5 mm (13.56 in)
Brakes
BRAKES
Specification Desc./Quantity
Front double stainless steel floating disc, Ø 320 mm (12.6 in), wawe
type, radially-mounted callipers with 4 differentiated and coun-
teracting plungers.
Rear Single stainless steel disc; Ø 282 mm (11.1 in)
GRISO 8V - 1200 Characteristics
CHAR - 13
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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 Sportec M3
Front 120/70 - ZR 17" 58 W
Inflation pressure (front) 2.3 bar (230 kPa) (33.4 PSI)
Inflation pressure with passenger (front) 2.3 bar (230 kPa) (33.4 PSI)
Rear 180/55 - ZR 17" 73 W
Inflation pressure (rear) 2.5 bar (250 kPa) (36.3 PSI)
Inflation pressure with passenger (rear) 2.5 bar (250 kPa) (36.3 PSI)
Supply
FUEL SUPPLY
Specification Desc./Quantity
FUEL SUPPLY Electronic injection (Weber . Marelli) with Stepper engine
Diffuser diameter: 50 mm (1.97 in)
Fuel premium unleaded petrol, minimum octane rating of 95
(NORM) and 85 (NOMM)
Tightening Torques
HEADS
Name Torque in Nm
Oil cap (2) 25 Nm (18.44 lbf ft)
Rocking lever support nut - M10x1.5 (8) 15 Nm (11.06 lbf ft) + 42 Nm (30.98 lbf ft)
Camshaft - rocking levers support fixing screws (12) 17 Nm (12.54 lbf ft)
Head fixing screw (4) - pre-tightening 15 Nm (11.06 lbf ft)
Head fixing screw (4) - final tightening 42 Nm (31 lbf ft)
Screw fixing head to chain compartment - M6x120 (4) 10 Nm (7.38 lbf ft)
Oil temperature sensor 11 Nm (8.11 lbf ft) - Loctite 243
Oil temperature sensor container 11 Nm (8.11 lbf ft) - Loctite 601
Head covers fixing screws (8) 8 Nm (5.9 lbf ft)
Spark plug (2) 30 Nm (22.13 lbf ft) - Molykote
CRANKCASE
Name Torque in Nm
Crankcase stud bolt - cylinder (8) 25 Nm (18.44 lbf ft)
Transmission side flange stud bolt - M8x66 (3) 35 Nm (25.81 lbf ft)
Transmission side flange stud bolt - M8x75 (2) 35 Nm (25.81 lbf ft)
Gear side crankshaft flange screw - TE M8x25 (8) 26 Nm (19.18 lbf ft)
Timing system cover screw - TCEI M8x55 (4) 25 Nm (18.44 lbf ft)
Timing system cover screw - TCEI M6x30 (10) 10 Nm (7.38 lbf ft)
Oil vapour union screw - TCEI M6x20 (2) 10 Nm (7.38 lbf ft)
TCEI M6x40 Screw (2) 10 Nm (7.38 lbf ft)
Timing sensor - TCEI M5x12 (2) 6 Nm (4.42 lbf ft)
Service shaft bearing locking screw (2) 10 Nm (7.38 lbf ft)
Oil pressure sensor (1) 25 Nm (18.44 lbf ft)
Screw fixing oil pressure sensor support - TCEI M10x20 (1) 18 Nm (13.28 lbf ft)
Oil cap (2) 25 Nm (18.44 lbf ft)
OIL SUMP
Name Torque in Nm
Oil pipe on sump reduction (1) 20 Nm (14.75 lbf ft)
Characteristics GRISO 8V - 1200
CHAR - 14
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Name Torque in Nm
Oil pipe on sump 20 Nm (14.75 lbf ft)
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)
Oil filter (1) 15 Nm (11.06 lbf ft)
Oil filter fitting (1) 40 Nm (29.5 lbf ft) - Loctite 243
Oil pipe in sump 20 Nm (14.75 lbf ft) - Loctite 648
Pressure-relief plug 40 Nm (29.5 lbf ft)
Cap on oil sump flange (2) 20 Nm (14.75 lbf ft)
Cap (1) 40 Nm (29.5 lbf ft)
CRANKSHAFT - FLYWHEEL
Name Torque in Nm
Connecting rod screw (4) - pre-tightening 40 Nm (29.5 lbf ft)
Connecting rod screw (4) - final tightening 80 Nm (59 lbf ft)
Screw fixing clutch disc on crankshaft - M8x25 (6) 42 Nm (30.98 lbf ft) - Loctite 243
Screw fixing clutch bell on disc - M7x16 (6) 20 Nm (14.75 lbf ft)
Start-up crown gear fixing screw (6) 10 Nm (7.38 lbf ft)
OIL PUMP
Name Torque in Nm
Oil pump fixing screws - M6x45 (3) 10 Nm (7.38 lbf ft)
Oil pump gear nut - M10x1.25 (1) 20 Nm (14.75 lbf ft)
Pressure-relief plug 40 Nm (29.5 lbf ft)
Cooling oil intake filter fixing screw (5) 10 Nm (7.38 lbf ft)
Lubrication oil intake filter fixing screw (2) 10 Nm (7.38 lbf ft)
TIMING SYSTEM
Name Torque in Nm
Service shaft flange screw - TBEI M6x14 (2) 8 Nm (5.9 lbf ft)
Timing system gear nut on service shaft - M18 (1) 150 Nm (110.6 lbf ft)
Timing system gear nut on crankshaft - M25 (1) 200 Nm (147.51 lbf ft)
Belt tension 50 Nm (36.88 lbf ft)
Timing system upper gear TE screw (2) 30 Nm (22.13 lbf ft)
Screw fixing timing system upper gear closing cap - TBEI
M5x10 (4) 7 Nm (5.16 lbf ft)
Cylinder chain tensioner cap (2) 30 Nm (22.13 lbf ft)
Screw fixing movable chain slider (2) 25 Nm (18.44 lbf ft)
Timing system outer cover screw - TCEI M6x16 (5) 10 Nm (7.38 lbf ft)
GENERATOR
Name Torque in Nm
Generator fixing screw - TCEI M8x45 (1) 22 Nm (16.23 lbf ft)
Generator fixing nut - M10x1.5 (1) 30 Nm (22.13 lbf ft)
Generator pulley nut on crankshaft - M16 (1) 80 Nm (59 lbf ft) - Loctite 243
GEAR
Name Torque in Nm
Gear shift cable lever nut 10 Nm (7.38 lbf ft)
Gear shift tie rod lever nut on gear pre-selector 10 Nm (7.38 lbf ft)
Gearbox to crankcase fixing nut - M8 (5) 20 Nm (14.75 lbf ft)
TE flanged screw fixing gearbox to crankcase - M8x45 (1) 20 Nm (14.75 lbf ft)
Oil cap M18x1.5 (1) 28 Nm (20.65 lbf ft)
Breather cap (1) 8 Nm (5.9 lbf ft)
Gear in neutral sensor (1) 10 Nm (7.38 lbf ft)
Oil drainage plug - M10x1 (1) 24 Nm (17.7 lbf ft)
Transmission shaft ring nut (1) 100 Nm (73.76 lbf ft)
OIL RADIATOR
Name Torque in Nm
Slot screw fixing oil radiator pipes - TCEI M10x20 (3) 20 Nm (14.75 lbf ft)
GRISO 8V - 1200 Characteristics
CHAR - 15
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Name Torque in Nm
Oil radiator spacer (1) 50 Nm (36.88 lbf ft)
Oil radiator fixing screws - M8x40 (3) 25 Nm (18.44 lbf ft)
Screws fixing oil radiator grille - TBEI M5x12 (4) 4 Nm (2.95 lbf ft)
Screws fixing oil radiator air deflector - TE M6x30 (3) 10 Nm (7.38 lbf ft)
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 6 -7 Nm
M6x25 TCEI DA screw 8 -12 Nm
CHASSIS
Name Torque in Nm
Front engine to chassis retainer 80 Nm
Transmission to chassis retainer (M12x250 + M12x230) 50 Nm
Right fixing plate - transmission retainer 25 Nm
Plate clamp - blow-by retainer 10 Nm
Coil plate retainer 10 Nm
Electronic control unit retainer 10 Nm
Bushings to electronic control unit retainer 10 Nm
Retainer for tank to chassis rear support rubber rings Manual
Filter casing fixing bolts 10 Nm
Left and right footrest plate to chassis upper retainer 25 Nm
Left and right footrest plate to chassis lower retainer 18 Nm
Brake switch on plate retainer Manual
Plate ring to plate retainer 6 Nm
Retainer for cable guide on right footrest plate 6 Nm
FOOTRESTS AND LEVERS
Name Torque in Nm
Footrest rubber retainer 10 Nm
Rider footrest sliding pin - M8 25 Nm
Passenger footrest support to lateral plates retainer 38 Nm
Rider heelrest to plates retainer 6 Nm
Passenger heelrest retainer 3 Nm
Rod retainer (nut) 10 Nm
Gear shift lever / brake pin retainer 10 Nm
Gear shift lever / pre-selector retainer 10 Nm
Gear shift lever - brake pin retainer 15 Nm
SIDE STAND
Name Torque in Nm
Stand plate to engine upper retainer 50 Nm
Stand plate to engine lower retainer 25 Nm
Side stand retainer pin 10 Nm
Switch fixing screw 10 Nm
Lock nut 30 Nm
Stand cable guide to engine retainer 50 Nm
Lateral lever arm retainer 10 Nm
SWING ARM
Name Torque in Nm
Fork on bushing clamp retainer 10 Nm
Fork on bevel gear pair retainer 50 Nm
Reaction rod to bevel gear pair retainer 50 Nm
Reaction rod to chassis retainer 50 Nm
Fork bolt to fork retainer 60 Nm
Characteristics GRISO 8V - 1200
CHAR - 16
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Name Torque in Nm
Preloading bushing to fork bolt retainer 10 Nm
FRONT SUSPENSION
Name Torque in Nm
Tube lock plate to steering base retainer 6 Nm
Fork stem on upper plate retainer 18 Nm
Upper and lower screws fixing fork stem on lower plate 22 Nm
Central screw fixing fork stem on lower plate 20 Nm
Headstock ring nut 40 Nm
Headstock counter ring nut manual + 90 degrees
Upper plate fixing cover 100 Nm
Fork hubs closing 25 Nm
REAR SUSPENSION
Name Torque in Nm
Shock absorber to chassis retainer - 8.8 50 Nm
Double connecting rod/shock absorber retainer - 10.9 40 Nm
Single connecting rod/double connecting rod retainer - 10.9 50 Nm
Single connecting rod to chassis retainer, 8.8 50 Nm
Double connecting rod/fork retainer - 10.9 50 Nm
AIR FILTER CASING
Name Torque in Nm
Blow-by expansion tank spacer to engine retainer 10 Nm
Blow-by expansion tank to spacer retainer 10 Nm
Filter housing to chassis retainer 10 Nm
EXHAUST
Name Torque in Nm
Exhaust pipe to engine retainer 25 Nm
Silencer to chassis connecting pipe retainer 25 Nm
Silencer to footrest support retainer 25 Nm
Protection to connecting pipe retainer 10 Nm
Lambda probe retainer 38 Nm
Clamp retainer 10 Nm
FRONT WHEEL
Name Torque in Nm
Wheel pin nut 80 Nm
Disc retainer 30 Nm
REAR WHEEL
Name Torque in Nm
Disc retainer 25 Nm
Rear wheel retainer, 10.9 110 Nm
FRONT BRAKING SYSTEM
Name Torque in Nm
Front brake right and left calliper retainer 50 Nm
REAR BRAKING SYSTEM
Name Torque in Nm
Rear brake calliper retainer 50 Nm
Rear brake fluid reservoir retainer 3 Nm
Rear brake fluid reservoir support to plate retainer 10 Nm
Rear brake rod lock nut manual
Brake pump retainer 10 Nm
GRISO 8V - 1200 Characteristics
CHAR - 17
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HANDLEBAR AND CONTROLS
Name Torque in Nm
Retainer for handlebar lower U-bolts on steering upper plate 50 Nm
Retainer for handlebar upper U-bolts 25 Nm
Anti-vibration weights retainer 10 Nm
Brake pump and clutch U-bolts retainer 10 Nm
Right and left light switch retainer 1.5 Nm
Clutch control cylinder to gear retainer 10 Nm
Rear-view mirror Manual
ELECTRICAL SYSTEM
Name Torque in Nm
Coil retainer 2 Nm
Horn retainer 15 Nm
Odometer sensor on bevel gear pair retainer 3 Nm
INSTRUMENT PANEL AND LIGHTS
Name Torque in Nm
Instrument panel support to light support retainer 10 Nm
Instrument panel support to fork upper plate retainer 10 Nm
Instrument panel retainer 3 Nm
Light support to fork lower plate retainer 25 Nm
Retainer for front and rear arrows 10 Nm
Headlamp retainer 15 Nm
Rear light to tail clamp retainer 3 Nm
FUEL PUMP FLANGE
Name Torque in Nm
Pump support to tank retainer 6 Nm
Tank breather joint 6 Nm
FUEL TANK
Name Torque in Nm
Filler to tank retainer 5 Nm
Cap ring nut to tank retainer 5 Nm
Screws on cap ring nut (aesthetic) 5 Nm
Tank to chassis front retainer 10 Nm
Battery housing and tank to chassis rear retainer 6 Nm
CHASSIS / FAIRINGS (FRONT)
Name Torque in Nm
Front mudguard retainer 6 Nm
Control unit protection retainer 6 Nm
Deflectors to chassis front upper retainer Manual
Deflectors to chassis front lower retainer Manual
Deflectors to chassis rear retainer Manual
Retainer fixing the deflectors to deflector clamp Manual
CHASSIS/ FAIRINGS (REAR)
Name Torque in Nm
reflector to support retainer 4 Nm
Retroreflector support to license plate holder retainer 4 Nm
License plate holder and light support retainer 4 Nm
License plate holder to lower clamp retainer manual
Tail section to chassis lower clamp retainer 25 Nm
Fuse bracket and relay support retainer 4 Nm
FINISHINGS
Name Torque in Nm
Ignition lock retainer - shear head screw - Nm
Characteristics GRISO 8V - 1200
CHAR - 18
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Overhaul data
Assembly clearances
Cylinder - piston assy.
Measurement of the cylinder diameter must be done at three heights, turning the dial gauge 90°.
Check that cylinders and pistons are of the same selection types (D, E, F).
Check clearance between cylinders and pistons on the selected diameter; if it exceeds the value speci-
fied, it is necessary to replace cylinders and pistons.
The pistons of an engine must be balanced; a weight difference of up to 1.5 g (0.0033 lb) is allowed.
PISTON - CYLINDER SELECTION TYPES
Specification Desc./Quantity
Piston diameter - selection D 94.935 - 94.945 mm (3.73759 - 3.73798 in)
Cylinder diameter - selection D 95.000 - 95.010 mm (3.74015 - 3.74054 in)
Piston diameter - selection E 94.945 - 94.955 mm (3.73798 - 3.73837 in)
Cylinder diameter - selection E 95.010 - 95.020 mm (3.74054 - 3.74093 in)
Piston diameter - selection F 94.955 - 94.965 mm (3.73837 - 3.73877 in)
Cylinder diameter - selection F 95.020 - 95.030 mm (3.74093 - 3.74133 in)
PIN - PISTON COUPLING
Specification Desc./Quantity
Pin diameter 21.998 - 21.994 mm (0.86606 - 0.86590 in)
Pin hole diameter on piston 22.016 - 22.011 mm (0.86677 - 0.86657 in)
Clearance between pin and holes on piston 0.013 - 0.022 mm (0.00051 - 0.00087 in)
GRISO 8V - 1200 Characteristics
CHAR - 19
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Piston rings
On each piston there are:
•1 top piston ring;
•1 middle piston ring;
•1 oil scraper piston ring.
Turn the rings so that the coupling ends are 120 degrees from each other.
CLEARANCE BETWEEN PISTON RINGS AND SEATS ON PISTON
Specification Desc./Quantity
Top ring 0.030 - 0.065 mm (0.00118 - 0.00256 in)
Middle ring 0.020 - 0.055 mm (0.00079 - 0.00216 in)
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:
•Top and middle piston ring: 0.40 - 0.65 mm (0.00158 - 0.00255 in)
•Oil scraper piston ring: 0.30 - 0.60 mm (0.00118 - 0.00236 in).
Crankcase - crankshaft - connecting rod
CRANKSHAFT SEAT (TIMING SYSTEM SIDE)
Specification Desc./Quantity
Diameter of crankshaft main journal, timing system side 37.975 - 37.959 mm (1.49507 - 1.49444 in)
Inside diameter of crankshaft bushing, timing system side 38.016 - 38.0 mm (1.49669 - 1.49606 in)
Clearance between bushing and main journal (timing system
side) 0.025 - 0.057 mm (0.00098 - 0.00224 in)
CRANKSHAFT SEAT ( CLUTCH SIDE)
Specification Desc./Quantity
Diameter of crankshaft main journal, clutch side 53.97 - 53.961 mm (2.12480 - 2.12444 in)
Inside diameter of crankshaft bushing on clutch-side flange 54.019 - 54.0 mm (2.12673 - 2.12598 in)
Clearance between bushing and main journal (clutch side) 0.030 - 0.058 mm (0.00118 - 0.00228 in)
Slot packing system
•Fitbothpistonsontheconnectingrods.
•Working from both sides, fit the gasket
between the crankcase and the cylin-
der on the crankcase.
•Fit both cylinders.
•TaketheleftcylinderpistontoTDCand
lock crankshaft rotation.
Specific tooling
020675Y Service shaft gear lock
Characteristics GRISO 8V - 1200
CHAR - 20
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