MOTO GUZZI NORGE 1200 User manual

SERVICE STATION MANUAL
854326
Norge 1200

SERVICE STATION
MANUAL
Norge 1200
While the basic features as described and illustrated in this manual remain unchanged, Moto Guzzi
s.p.a. reserves the right to introduce changes to their own models at any time. All rights regarding
electronic data storage, total or partial reproduction or adaptation of this manual by any means are
reservedforallCountries.Thirdpartyproductsorservicesreferredtointhismanualshouldbeconsidered
onlyinformative andare notbinding. MotoGuzzi s.p.a.shall notbe liablefor anyfunctions oruse ofthese
products.
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SERVICE STATION MANUAL
Norge 1200
This manual provides the main information to carry out regular maintenance operations on your scooter.
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 Sectionsmarkedwith thissymbol indicatethe correctuseof thevehicle
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.

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
BODYWORK BODYW

INDEX OF TOPICS
CHARACTERISTICS CHAR

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,APOISONOUS GASWHICHCANCAUSE
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
Characteristics Norge 1200
CHAR - 2

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
•Beforedismantlingcomponents, removedirt, mud,dust and foreignbodies fromthe 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.
Norge 1200 Characteristics
CHAR - 3

•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.
•Ifthere aresigns ofdirt, rust,humidity, etc.,clean theconnector internalparts carefullyusing
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
Characteristics Norge 1200
CHAR - 4