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SERVICE STATION MANUAL

854378

GRISO 8V - 1200

Summary of content (266 pages)

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SERVICE STATION MANUAL 854378 GRISO 8V - 1200
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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.
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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.
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Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten
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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 POWER SUPPLY ENG P SUPP SUSPENSIONS SUSP CHASSIS CHAS BRAKING SYSTEM BRAK SYS CLUTCH SYSTEM CLU SYS BODYWORK BODYW PRE-DELIVERY PRE DE Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten
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INDEX OF TOPICS CHARACTERISTICS Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten CHAR
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GRISO 8V - 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. CAUTION EXHAUST EMISSIONS CONTAIN CARBON MONOXIDE, A POISONOUS GAS WHICH CAN CAUSE LOSS OF CONSCIOUSNESS AND EVEN DEATH.
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GRISO 8V - 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 SYSTEMS. BRAKE AND CLUTCH FLUIDS ARE EXTREMELY HARMFUL FOR YOUR EYES. IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THEM IMMEDIATELY WITH ABUNDANT COLD, CLEAN WATER AND SEEK MEDICAL ADVICE IMMEDIATELY.
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GRISO 8V - 1200 • Characteristics 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, OTHERWISE THEY NEED REPLACING. • Only use ORIGINAL Moto Guzzi SPARE PARTS. • Comply with lubricant and consumables usage guidelines.
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GRISO 8V - 1200 Characteristics 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 ALWAYS USE A TORQUE WRENCH TO REASSEMBLE THESE COMPONENTS.
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GRISO 8V - 1200 Characteristics 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 Y year 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.
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GRISO 8V - 1200 Characteristics Specification Compression ratio Start-up Engine revs at idle speed Clutch Desc.
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GRISO 8V - 1200 Characteristics Specification Instrument panel lighting License plate light Turn indicator warning light Gear in neutral warning light Alarm warning light - Gear shift Side stand down warning light Low fuel warning light High-beam warning light Oil pressure warning light Desc./Quantity LED 12V - 5 W LED LED LED LED LED LED LED Frame and suspensions CHASSIS Specification Type Trail Headstock angle Front Wheel travel Rear Wheel travel Desc.
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GRISO 8V - 1200 Characteristics Wheels and tyres WHEELS AND TYRES Specification Type Front wheel rim Rear wheel rim Tyres Front Inflation pressure (front) Inflation pressure with passenger (front) Rear Inflation pressure (rear) Inflation pressure with passenger (rear) Desc./Quantity hollow 3-spoke rim in chilled cast aluminium alloy 3.50" x 17'' 5.50" x 17" METZELER Sportec M3 120/70 - ZR 17" 58 W 2.3 bar (230 kPa) (33.4 PSI) 2.3 bar (230 kPa) (33.4 PSI) 180/55 - ZR 17" 73 W 2.5 bar (250 kPa) (36.
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GRISO 8V - 1200 Characteristics Name Oil pipe on sump Oil sump lower screw - TCEI M6x30 (4) Oil sump screw - TCEI M6x55 (14) Oil sump screw - TCEI M6x60 (2) Oil drainage plug - M10x1 (1) Oil filter (1) Oil filter fitting (1) Oil pipe in sump Pressure-relief plug Cap on oil sump flange (2) Cap (1) Torque in Nm 20 Nm (14.75 lbf ft) 10 Nm (7.38 lbf ft) 10 Nm (7.38 lbf ft) 10 Nm (7.38 lbf ft) 20 Nm (14.75 lbf ft) 15 Nm (11.06 lbf ft) 40 Nm (29.5 lbf ft) - Loctite 243 20 Nm (14.
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GRISO 8V - 1200 Characteristics Name Oil radiator spacer (1) Oil radiator fixing screws - M8x40 (3) Screws fixing oil radiator grille - TBEI M5x12 (4) Screws fixing oil radiator air deflector - TE M6x30 (3) Torque in Nm 50 Nm (36.88 lbf ft) 25 Nm (18.44 lbf ft) 4 Nm (2.95 lbf ft) 10 Nm (7.
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GRISO 8V - 1200 Characteristics Name Preloading bushing to fork bolt retainer Torque in Nm 10 Nm FRONT SUSPENSION Name Tube lock plate to steering base retainer Fork stem on upper plate retainer Upper and lower screws fixing fork stem on lower plate Central screw fixing fork stem on lower plate Headstock ring nut Headstock counter ring nut Upper plate fixing cover Fork hubs closing Torque in Nm 6 Nm 18 Nm 22 Nm 20 Nm 40 Nm manual + 90 degrees 100 Nm 25 Nm REAR SUSPENSION Name Shock absorber to chassis
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GRISO 8V - 1200 Characteristics HANDLEBAR AND CONTROLS Name Retainer for handlebar lower U-bolts on steering upper plate Retainer for handlebar upper U-bolts Anti-vibration weights retainer Brake pump and clutch U-bolts retainer Right and left light switch retainer Clutch control cylinder to gear retainer Rear-view mirror Torque in Nm 50 Nm 25 Nm 10 Nm 10 Nm 1.
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GRISO 8V - 1200 Characteristics 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 specified, 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.
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GRISO 8V - 1200 Characteristics 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 Top ring Middle ring Oil scraper ring Desc./Quantity 0.030 - 0.065 mm (0.00118 - 0.00256 in) 0.020 - 0.055 mm (0.00079 - 0.00216 in) 0.010 - 0.045 mm (0.00039 - 0.
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GRISO 8V - 1200 • Characteristics Thoroughly clean the upper surface of both cylinders. • Place the tool on the left cylinder to determine the "squish" (X). • Fasten the tool with the nuts of the stud bolts. Specific tooling 020676Y Comparator support for piston position checking • Reset the micrometer on the cylinder rim. • Move the tool so that the micrometer feeler reaches the top point of the piston crown.
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GRISO 8V - 1200 Characteristics Recommended products chart RECOMMENDED PRODUCTS Product AGIP RACING 4T 10W-60 AGIP GEAR SAE 80 W 90 AGIP GEAR MG/S SAE 85 W 90 AGIP FORK 7.5W AGIP GREASE SM2 Neutral grease or petroleum jelly. AGIP BRAKE 4 / BRAKE 5.1 AGIP BRAKE 4 / BRAKE 5.1 Description Engine oil Specifications SAE 10W - 60. As an alternative for recommended oils, use top-branded oils that meet or exceed the requirements of CCMC G-4 API SG specifications.
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INDEX OF TOPICS SPECIAL TOOLS Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten S-TOOLS
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GRISO 8V - 1200 Special tools SPECIAL TOOLS Stores code 020677Y Description Alternator belt tensioner 05.91.17.30 Front cover insertion cone 020716Y Connecting rod locking 020470Y Pin snap ring fitting tool 05.92.72.30 Timing system cover sealing ring punch 01.92.91.
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GRISO 8V - 1200 Special tools Stores code 05.90.25.30 Description 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.
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GRISO 8V - 1200 Special tools Stores code 14.92.71.00 Description Tool to fit the sealing ring on the flywheelside flange 12.91.20.00 Tool to fit the flywheel-side flange together with sealing ring on the crankshaft 19.92.71.
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GRISO 8V - 1200 Special tools Stores code 020676Y Description Comparator support for piston position checking 020678Y Tool for clutch rod checking 05.91.26.30 Tool for tightening the fork pin ring nut clutch hub AP8140190 Tool for steering tightening 05.90.27.30 Gearbox support 05.90.27.31 Gearbox oil seal buffer 05.90.27.
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GRISO 8V - 1200 Special tools Stores code 05.90.27.33 Description Ball joint sealing buffer 05.90.27.34 Wrench for pinion ring nut 05.90.27.35 Pinion oil seal buffer 05.90.27.
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GRISO 8V - 1200 Special tools Stores code AP8140148 Description Spacer-pumping element separating plate AP8140149 Protection for fitting operations AP8140150 Perforated rod for pumping member air bleed AP8140151 Complete tool kit for fork S-TOOLS - 29 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten
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INDEX OF TOPICS MAINTENANCE Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten MAIN
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GRISO 8V - 1200 Maintenance Maintenance chart NOTE CARRY OUT THE MAINTENANCE OPERATIONS AT HALF THE INTERVALS SHOWN IF THE VEHICLE IS USED IN WET OR DUSTY AREAS, OFF ROAD OR FOR SPORTS APPLICATIONS.
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GRISO 8V - 1200 Maintenance Action Wheel bearings - Check and clean, adjust, grease or replace if necessary Disc brakes - Check and clean, adjust or replace if necessary Air filter - Check and clean, adjust, grease or replace if necessary Engine oil filter - Replace General vehicle operation - Check and clean, adjust, grease or replace if necessary.
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GRISO 8V - 1200 Maintenance THE UNIT MUST BE HOT WHEN THE OIL IS CHANGED AS UNDER SUCH CONDITIONS OIL IS FLUID AND THEREFORE EASY TO DRAIN. NOTE RIDE SOME km (miles) TO WARM UP ENGINE OIL • Place a container with + 400 cm³ (25 cu in) capacity under the drainage plug (3). • Unscrew and remove the drainage plug (3). • Unscrew and remove the breather cap (2). • Drain the oil into the container; allow several minutes for oil to drain out completely.
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GRISO 8V - 1200 Maintenance • Shut off the engine. • Keep the vehicle upright with the two wheels on the ground. • Unscrew and remove the dipstick (1). • Clean the dipstick (1). • Reinsert the dipstick (1) into the opening but do not screw it. • Remove the dipstick (1). • Check oil level on the dipstick (1). • The oil level is correct when it close to the "MAX" mark. MAX = maximum level MIN = minimum level Add engine oil if required: • Unscrew and remove the dipstick (1).
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GRISO 8V - 1200 • Unscrew and remove the filler plug (1). • Drain the oil into the container; allow Maintenance several minutes for oil to drain out completely. • Check and if necessary, replace the sealing washers of drainage plug (2). • Remove any metal scrap attached to the drainage plug (2) magnet. • Screw and tighten the drainage plug (2). • Pour new engine oil until it goes above the minimum level marked "MIN". • Screw the filler cap (1).
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GRISO 8V - 1200 Maintenance • Shut off the engine. • Keep the vehicle upright with both wheels on the ground. • Unscrew and remove the cap/dipstick (1) placed on the gearbox right side. • • The level is correct if the oil is on the rim of the hole of the cap/dipstick (1). If necessary: • Top-up with oil until it reaches the dipstick opening (1). CAUTION 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.
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GRISO 8V - 1200 Maintenance Air filter • Disconnect the air temperature sensor connector. • Slide off and remove the main fuse box from its holder. • Undo and remove the six screws. • Lift the filter housing cover.
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GRISO 8V - 1200 Maintenance • Remove the air filter frame. • Remove the air filter. • Cover the inlet duct with a clean cloth so that no foreign bodies get into the inlet ducts. DO NOT START THE ENGINE WITHOUT THE AIR FILTER. TO CLEAN THE FILTERING ELEMENT, USE A PRESSURE AIR JET FROM THE INSIDE TO THE OUTSIDE. Checking the valve clearance If the timing system is very noisy, check the clearance between the valves and the rocking levers.
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GRISO 8V - 1200 • Maintenance Undo and remove the four head cover fixing screws and collect the sealing Orings. • Remove the head cover together with the gasket. • Loosen the nut (1). • Use a screwdriver to act on the set screw (2) until the following clearances are obtained: Inlet valve: 0.10 mm (0.0039 in) Outlet valve: 0.15 mm (0.0059 in) • The measurement must be done using a special thickness gauge . CAUTION IF CLEARANCE IS LARGER THAN RECOMMENDED, THE TAPPET WILL BE NOISY.
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GRISO 8V - 1200 Maintenance Top-up Front brake: • Undo the two screws (1) of the brake fluid reservoir (2) using a Phillips screwdriver. • Lift and remove the cover (3) and screws (1) as well. • Remove the gasket (4). Rear brake: • Unscrew and remove the cap (5). • Remove the gasket (6). • Top-up the reservoir with brake fluid to the correct level, which is between the two "MIN" and "MAX" reference marks. RISK OF BRAKE FLUID SPILLS.
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GRISO 8V - 1200 Maintenance MAIN - 41 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten
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INDEX OF TOPICS ELECTRICAL SYSTEM Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten ELE SYS
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GRISO 8V - 1200 Electrical system Components arrangement Key: 1 Coil 2 Instrument panel 3 Fuel pump 4 Injector ELE SYS - 43 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten
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Electrical system GRISO 8V - 1200 5 Throttle valve potentiometer 6 Fall sensor 7 Rear light 8 Main fuses 9 Lambda probe 10 Battery 11 Starter motor 12 Intake air temperature sensor 13 Engine revolution sensor 14 Head temperature sensor 15 Engine control unit 16 Instrument panel air temperature sensor 17 Front headlamp 18 Alternator 19 Oil pressure sensor 20 Speed sensor 21 Auxiliary fuses Electrical system installation INTRODUCTION Scope and applicability The position of the cable harnesses, how they are
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GRISO 8V - 1200 Electrical system Central part TABLE A - LAMBDA PROBE • Fasten the lambda probe cable harness to the chassis but do not tauten it. TABLE A1 - LAMBDA PROBE • Fasten the lambda probe cable harness to the engine oil breather pipe but do not tauten it. TABLE B - SIDE STAND SENSOR • Fasten the side stand sensor cable harness to the stand plate using two clamps.
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Electrical system GRISO 8V - 1200 General wiring diagram Key: 1. Multiple connectors 2. Start-up relay 3. Maintenance relay 4.
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GRISO 8V - 1200 Electrical system 5. Right light switch 6. Light relay 7. GPS coupling 8. Horn 9. Left light switch 10.Instrument panel air temperature thermistor 11.Instrument panel 12.Instrument panel diagnosis 13.Key switch 14.Immobilizer aerial 15.Right rear turn indicator 16.Rear light (LED) 17.Left rear turn indicator 18.License plate light 19.Rear stop switch 20.Front stop switch 21.(ECU) Diagnosis connector 22.Auxiliary fuses 23.Main fuses 24.Starter motor 25.Battery 26.27.Alternator 28.
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Electrical system GRISO 8V - 1200 43.Left cylinder spark plug 44.Right cylinder coil 45.Left cylinder coil 46.Right cylinder injector 47.Left cylinder injector 48.Speed sensor 49.Fall sensor 50.Flywheel pick up 51.Pick-up wire shielding 52.ECU 53.Left front turn indicator 54.Tail light bulb 55.High-/low-beam bulb 56.Front headlamp 57.
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GRISO 8V - 1200 Electrical system Resetting the CODE This function is used to set a new code when the old one is not available; in this case, at least two of the programmed keys have to be inserted in the ignition lock. After the first key has been inserted, the second one is requested with the following message: INSERT KEY II If the second key is not inserted within 20 seconds, the operation is finished.
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Electrical system GRISO 8V - 1200 Injector 2 Error DC V DC ECU 30 Pump Relay Error ECU 36 Local Loopback Error ECU 37 Start-up Remote Error DC V DC ECU 44 Remote Error Start-up DC Gnd ECU 45 Canister Error DC V DC ECU 46 Canister Error DC Gnd ECU 47 Battery Error Hig ECU 50 Generic ECU Error ECU 51 Rpm Sensor Error ECU 54 Self-adaptability Value Error ECU 55 Vehicle Speed Error ECU 56 Stepper Error AC ECU 60 Stepper Error DC V DC ECU 61 Stepper Error DC Gnd ECU 62 Not recognised error ECU 00 INSTRUMENT PA
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GRISO 8V - 1200 Electrical system INSTRUMENT PANEL SOFTWARE UPGRADE This function is used to program the instrument panel again with a new software through Axone. The Display reads: "Instrument panel disconnected. Now connect the diagnosis instrument"; the instrument panel will connect normally after the key is extracted-inserted. The white connector is placed under the saddle, beside the fuse box, close to the diagnosis connector for the injection system.
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Electrical system GRISO 8V - 1200 Start-up system check pick-up input about 100 A level indicators Petrol pump: Input: 3.5 A (to be measured between pins 1 and 2 with 12V voltage) Fuel level sensor: Resistance (to be measured between pins 3 and 4) 250-300 Ohm with fuel level equal to 0 litre 100 Ohm with fuel level equal to 11.25 litres (20.43 pt) 10-20 Ohm with fuel level equal to 22.5 litres (40.86 pt) The low fuel warning light turns on with values over 230 Ohm.
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GRISO 8V - 1200 Electrical system REAR LIGHT LED Fuses AUXILIARY FUSES A - Stop, horn, lights, coil, light relay (15 A). B - Tail lights, license plate light, passing, ignition relay (15 A). C - Fuel pump, coils, injectors (15 A). D - Lambda burner, secondary injection relay coil, start-up relay coil, speed sensor power supply, ECU control unit power supply, engine kill (15 A). E - Permanent positive, ECU power supply (3A). MAIN FUSES 1 - From battery to voltage regulator (30 A).
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Electrical system GRISO 8V - 1200 Control unit Model: Magneti Marelli IAW 5 AM2 BROWN connector pin configuration Pin Use 1 Not used 2 Not used 3 Ignition potentiometer signal 4 Not used 5 Engine temperature signal 6 Not used 7 Not used 8 Not used 9 Stepper motor (+) 10 Right cylinder coil control 11 Not used 12 Not used 13 Not used 14 Air temperature signal 15 Not used 16 Not used 17 Stepper motor (+) 18 Stepper motor (-) 19 Stepper motor (-) 20 5V power supply (NTC sensors) 21 Not used 22 Not used 23 N
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GRISO 8V - 1200 Electrical system 27 Not used 28 Left cylinder injector control 29 Ignition potentiometer power supply 30 Not used 31 Not used 32 Ignition potentiometer negative 33 Not used 34 Revolution sensor anti-jamming cable 35 Engine revolution sensor signal 36 Not used 37 Right cylinder injector control 38 Left cylinder coil control BLUE connector pin configuration Pin Use 1 Pin 85 ignition relay control 2 Not used 3 Not used 4 Power supply protected from instrument panel 5 Not used 6 Pin 86 auxili
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Electrical system GRISO 8V - 1200 25 Not used 26 Not used 27 "Engine stop" signal input 28 Ignition signal input 29 CAN - L line (ccm/instrument panel) 30 Not used 31 Not used 32 Oxygen probe power supply 33 Clutch sensor signal 34 Not used 35 Fall sensor signal 36 Not used 37 Not used 38 Side stand sensor signal Battery 12 V - 18 Ampere/hour Speed sensor Function To indicate the vehicle speed by reading the rear wheel turning speed.
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GRISO 8V - 1200 • Electrical system sensor: on swingarm, right side, near the rear brake calliper • connector: under the saddle, next to the right fairing Pin-out: • PINS 1-3 Voltage: approx. 12 V • PINS 2-3 Voltage: variable 0.4V-12V (by turning the rear wheel) PIN: 1. Supply voltage (green) 2. Output signal (grey/white) 3. Ground (blue/orange) AXONE: ELECTRICAL ERRORS Speed sensor - invalid signal.
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Electrical system GRISO 8V - 1200 Engine rpm sensor Function It informs crankshaft position and speed to the Marelli control unit. Operation / Operating principle Inductive sensor: sinusoidal-type generated voltage; two teeth are missing on the flywheel for the reference position.
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GRISO 8V - 1200 Electrical system if there is not continuity, restore the cable harness; if there is continuity, check the interruption on the sensor and replace it. WARNING If the electric circuit is short-circuited, no error is displayed. Check the sensor electrical specifications: If they are not correct, replace the sensor. If correct, check supply insulation and ground connection insulation of both cables. Perform the tests from the sensor connector towards the sensor.
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Electrical system GRISO 8V - 1200 AXONE: PARAMETERS Throttle Example value: 4.9° AXONE: STATUSES Throttle position Example value:Released/Pressed/Full load It indicates if the throttle potentiometer is open or closed in the released position. AXONE: ELECTRICAL ERRORS Throttle actuator position sensor P0120 Example value:open circuit, shorted to positive / shorted to negative. Error cause • If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 3 of connector A (BROWN).
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GRISO 8V - 1200 Electrical system Engine temperature sensor Function tells the engine temperature to the control unit so as to optimise carburetion and idle control Operation / Operating principle NTC type sensor (resistance sensor, inversely variable with temperature) Level in wiring diagram:Temperature sensors Location: • Sensor: on the right cylinder, inside the "V" • Connector: on the sensor Electrical characteristics: ENGINE TEMPERATURE SENSOR RESISTANCE Specification Resistance at -40 °C (-104
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Electrical system GRISO 8V - 1200 In case of recovery, this value is set by the control unit. ELECTRICAL ERRORS engine temperature sensor P0115 - open circuit, shorted to positive / shorted to negative. Error cause • If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 5 of the BROWN connector.
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GRISO 8V - 1200 Electrical system Air temperature sensor Function It tells the control unit the intake air temperature in order to calculate oxygen presence so as to optimise the petrol quantity necessary for correct combustion. Operation / Operating principle NTC type sensor (resistance sensor, inversely variable with temperature).
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Electrical system GRISO 8V - 1200 the sensor; if it is not OK, replace the sensor; if it is OK, check continuity between PIN 14 of the BROWN connector and PIN 2 of sensor: restore cable harness if there is not continuity; if it is OK, reconnect the control unit connector and, with key set to key ON, check the continuity between the sensor connector PIN 1 and the vehicle ground connection: if there is not continuity, restore the cable harness; if there is continuity, it means that the cause of the error is
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GRISO 8V - 1200 Electrical system 1. Sensor signal + (black wire) 2. Sensor signal - (grey wire) 3. Heater ground connection (white) 4. Heater power supply (white) AXONE: PARAMETERS Lambda probe Example value: 0 - 1000 mV If there is a short circuit at + 5 V or above, the value read is approx. 5.000 mV. If there is a short circuit to ground instead, the value read is equal to 0 mV and the Lambda Sensor Correction parameter shows 25%: no error is displayed, though.
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Electrical system • GRISO 8V - 1200 if shorted to positive: disconnect the probe connector and check the sensor correct resistance: replace the sensor if not OK; if it is OK, restore the cable harness. • if the circuit is open, shorted to negative: check the continuity from probe connector (PIN 3 and 4) towards the probe: if not OK, replace the probe; if it is correct, check the sensor connector and the Marelli control unit connector. If not OK, restore.
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GRISO 8V - 1200 Electrical system The auxiliary injection relay (No. 31 in the wiring diagram, placed on the front right side of the motorcycle, in the auxiliary fuses/relays box, first relay to the left starting from the front; CHECK, however, the identification of the relay with the colour of the cables) is energised for 5 seconds and the grey/red cable of the injector is closed to ground for 4 ms per second.
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Electrical system • GRISO 8V - 1200 If shorted to positive: excessive voltage has been detected at PIN 37 of the BROWN connector. • If shorted to negative: no voltage has been detected. • If the circuit is open: an interruption has been detected. Troubleshooting • if shorted to positive: disconnect the injector connector, take the key to ON and check if there is voltage on the blue/red cable: if there is voltage, restore the cable harness. If there is no voltage, replace the injector.
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GRISO 8V - 1200 Electrical system 2. Circuit earthing AXONE: PARAMETERS Left coil ignition advance. AXONE: ACTIVATION Left coil: The auxiliary injection relay (No. 29 in the wiring diagram, placed under the right side fairing of the motorcycle; CHECK, however, the identification of the relay with the colour of the cables) is energised for 5 seconds and the green/orange cable of the coil is closed to ground for 2 ms per second.
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Electrical system GRISO 8V - 1200 AXONE: ELECTRICAL ERRORS Right coil P0352 - shorted to positive / open circuit, shorted to negative. Error cause • If shorted to positive: excessive voltage has been detected at PIN 10 of the (BROWN) connector. • If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 10 of the (BROWN) connector.
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GRISO 8V - 1200 • Electrical system An oil sensor failure is signalled when, with engine off, it is detected that the sensor circuit is open. The test is performed only once when the key is set to ON. This error is signalled by the bulb icon and the general warning light turns on as well. Troubleshooting • Check the sensor connector and the instrument panel connector (PIN 17): If not OK, restore.
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Electrical system GRISO 8V - 1200 Gear in neutral Example value:yes/no DIAGNOSIS • Indication on the instrument panel always gear engaged: check the control unit connector and the sensor connector: if they are not OK, restore the cable harness; if OK, disconnect the connector and, with gear in neutral, check continuity to ground of the terminal, sensor side: if there is not continuity, replace the sensor (after checking cable harness continuity on the sensor side and the correct mechanical position); if
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GRISO 8V - 1200 Electrical system Example value:Yes/No The statuses regularly viewed are YES / NO DIAGNOSIS Troubleshooting: • Indication on Axone always NO: check the correct position of the cable terminals on the sensor and the correct connection of the cables on the terminals.
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Electrical system • GRISO 8V - 1200 Indication on Axone always EXTENDED: check the side stand sensor connector and the ECU connector: if they are not OK, restore; if OK, disconnect both terminals from the sensor and check continuity to ground of PIN 1 (blue/green, cable harness side): if there is not continuity, restore the cable harness; if there is, check continuity of the green/brown cable: if it is not OK, restore; if OK, replace the sensor.
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GRISO 8V - 1200 • Electrical system Indication on Axone always Normal, even when the sensor is inverted: disconnect the connector and, with sensor inverted, check if there is continuity between the two PINS of the sensor: if there is no continuity, replace the sensor; if there is, check the connector.
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Electrical system GRISO 8V - 1200 and the instrument panel connector PIN 10: if not OK, restore the cable harness; if OK, check the correct sensor resistance: if it is not OK, replace the sensor; if it is OK, check continuity of the brown cable between the sensor connector (cable harness side) and PIN 18 of the instrument panel connector: If not OK, restore the cable harness; if OK, with key set to ON, check if there is voltage at the sensor connector PIN 1: if there is no voltage, replace the instrument
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GRISO 8V - 1200 • Electrical system Sky blue/orange cable (cable harness side): 0V voltage if engine kill in STOP; 12V if engine kill in RUN. • Red/black cable (cable harness side): always 12 V voltage CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL CONCEPTS OF ELECTRICAL TROUBLESHOOTING FOUND AT THE BEGINNING OF THE CHECKS AND CONTROLS SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
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Electrical system GRISO 8V - 1200 3 HIGH-BEAM LIGHT INPUT 456 K LINE 78 SELECT 1 - SET 9 FUEL LEVEL SENSOR 10 AIR TEMPERATURE SENSOR 11 + BATTERY 12 LEFT TURN INDICATOR CONTROL 13 14 15 16 GENERAL EARTH CONNECTION 17 OIL PRESSURE SENSOR INTAKE 18 SENSORS EARTH CONNECTION 19 GENERAL GROUND (OPTIONAL) 20 GENERAL GROUND (OPTIONAL) The pin configuration of the black-bodied connector is as follows: PIN USE 21 + BATTERY 22 LEFT FRONT TURN INDICATOR ACTIVATION 23 LEFT REAR TURN INDICATOR ACTIVATION 24 AERIAL 1 2
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GRISO 8V - 1200 Electrical system 39 40 SELECT 3 ELE SYS - 79 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten
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INDEX OF TOPICS ENGINE FROM VEHICLE Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten ENG VE
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GRISO 8V - 1200 Engine from vehicle Vehicle preparation Before removing the engine block, proceed as follows: • From the back, secure the vehicle with belts attached to a hoist. • From the front, secure the vehicle with belts attached to the handlebar and fixed to the work bench. • Place the engine service stand under the oil sump. • Remove the exhaust system, the fork with cardan shaft and the fuel tank. Removing the engine from the vehicle • Disconnect the spark plug tubes.
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Engine from vehicle • GRISO 8V - 1200 Disconnect the engine temperature sensor connector • Disconnect the revolution sensor connector. • Disconnect the alternator connectors. • Disconnect the neutral sensor connector.
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GRISO 8V - 1200 • Engine from vehicle Undo and remove the two screws and collect the washers. • Remove the starter motor cover. • Unscrew and remove the stud bolt. • Disconnect the ground leads. • Disconnect the starter motor connectors. • Undo and remove the three screws and remove the clutch control cylinder. • Lock the cylinder using a clamp to prevent oil leaks. • Slide off the gearbox oil breather pipe.
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Engine from vehicle • GRISO 8V - 1200 Working on both sides, release the clamp and slide off the engine oil breather pipe. • Undo and remove the two screws fixing the oil vapour union. • Remove the oil vapour union. • Disconnect the stand sensor connector and release it from the clamps. • Undo and remove the two screws and remove the control unit protection. • Undo and remove the two screws and move the control unit downwards.
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GRISO 8V - 1200 • Engine from vehicle Undo and remove the screws and move the oil vapour recovery reservoir. • Unscrew and remove the stud bolt. • Slide off the oil pipe from the blow-by tank and keep it fitted to the oil sump. • Slide off the blow-by tank from the two hooks on the chassis. • Working from both sides, undo and remove the three inlet manifold screws. • Collect the gasket. • Remove both footrest holding plates.
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Engine from vehicle • GRISO 8V - 1200 Undo and remove the two screws and collect the cable guide. • Remove the plate. CAUTION PERFORM THE OPERATIONS BELOW HELPED BY A SECOND OPERATOR. • Working on both sides, undo and remove the front screw and collect the washer. • Unscrew and remove the engine upper fixing nut and collect the washer. • Remove the upper bolt and collect the washer. • Lower the engine partially. • Disconnect the oil pressure sensor connector. • Lower the engine completely.
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GRISO 8V - 1200 Engine from vehicle Installing the engine to the vehicle • Place the vehicle chassis over the engine with the gear. • From the back, secure the chassis with belts attached to a hoist. • From the front, secure the vehicle with belts attached to the handlebar and fixed to the work bench. • Lift the engine placing it in position. • Connect the oil pressure sensor connector. • Working from the left side, fit the engine upper bolt with the washer.
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Engine from vehicle • GRISO 8V - 1200 Working from the left side, fit the engine lower bolt with the washer. • From the opposite side, fit the washer and tighten the nut. • Working on both sides, tighten the front screw to the prescribed torque. • Tighten the stud bolt. • Place the oil vapour recovery reservoir and tighten the screw. • Fit the control unit and tighten the two screws. • Fit the control unit cover and tighten the two screws.
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GRISO 8V - 1200 • Engine from vehicle Working from both sides, place the inlet manifold fitting a new gasket between the manifold and head. • Fasten the inlet manifold with the three screws. • Connect the stand sensor connector and fix it to the chassis with new clamps. • Place the oil vapour union and tighten the two fixing screws. • Insert the oil breather pipe and fasten it with a new clamp.
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Engine from vehicle • Fit the gearbox oil breather pipe. • Fit the clutch control cylinder. • Tighten the three screws. • Connect the starter motor connectors. • Connect the ground cables and tighten GRISO 8V - 1200 the screw. • Fit the starter motor cover. • Place the two washers and tighten the two screws.
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GRISO 8V - 1200 • Connect the neutral sensor connector. • Connect the alternator connectors. • Connect the revolution sensor connec- Engine from vehicle tor. • Connect the engine temperature sensor connector.
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Engine from vehicle • GRISO 8V - 1200 Connect and adjust the throttle grip cable clearance. • Place the fork with cardan shaft and the rear wheel. • Working on both sides, connect the injector connectors. • Working from both sides, connect the spark plug tube. • Install the fuel tank. • Fit the saddle. • Working from both sides, fit the fairing and tighten the three screws. • Install the complete exhaust.
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INDEX OF TOPICS ENGINE Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten ENG
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Engine GRISO 8V - 1200 Gearbox Diagram Key: 1.
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GRISO 8V - 1200 Engine 2. Circlip 3. Thickness 4. Pin 5. Complete desmodromic 6. Ball bearing 7. Spring 8. Spacer 9. Circlip 10.Fifth wheel 11.Linking pin 12.Gear 13.Circlip 14.Thrust washer 15.Ball bearing cage 16.Gear 17.Sealing ring 18.Ball bearing 19.Gear 20.Circlip 21.Clutch shaft 22.Ball bearing 23.Oil plug 24.Washer 25.Gearbox 26.Aluminium washer 27.Breather cap 28.Neutral sensor 29.Gasket 30.Sealing ring 31.Bushing 32.Gasket 33.Oil drainage plug 34.Sealing ring 35.Thrust bearing 36.
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GRISO 8V - 1200 Engine 40.Index lever 41.Spring 42.Ball bearing 43.Gear 44.Gear 45.Ball bearing cage 46.Thrust washer 47.Circlip 48.Gear 49.Circlip 50.Gear 51.Main shaft 52.Transmission gear 53.Fork (5th - 1st) 54.Fork shaft 55.Fork (3rd - 4th) 56.Fork (2nd - 4th) 57.Gear 58.Gear 59.Ball bearing 60.Transmission shaft 61.Gear 62.Spacer Gearbox Removing the gearbox • Remove the starter motor. • Make sure the transmission is in idle. • Undo and remove the screw and remove the gearbox lever.
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GRISO 8V - 1200 • Engine Unscrew and remove the gearbox oil filler cap. • Place a container of suitable capacity under it, unscrew and remove the cap and then bleed all gearbox oil. • Loosen and turn the oil pipe fitting on the sump. • Undo and remove the three screws.
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GRISO 8V - 1200 Engine • Undo and remove the two screws. • Undo and remove the screw. • Remove the gearbox.
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GRISO 8V - 1200 Engine Disassembling the gearbox • Remove the gearbox. • Unscrew and slide off the odometer gear and collect the abutment washer that is inside the gearbox. • From the outside, slide off the thrust cylinder and collect the O-Ring and the washer. • Remove the thrust bearing and the washer.
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GRISO 8V - 1200 Engine • Slide off the rod with the two bushings. • Undo and remove the five external screws. • Place the gearbox on the specific gearbox support tool and on a vice. Specific tooling 05.90.25.30 Gearbox support • Undo and remove the nine internal screws. • Open the gearbox.
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GRISO 8V - 1200 • Engine Remove the bearings from the gearbox if necessary. • Release the spring. • Pressing the selector, slide off the whole transmission lever. • Use rubber bands to tie down the transmission shaft unit and extract it. • 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.
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GRISO 8V - 1200 Engine • Remove the forks and collect the shaft.
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GRISO 8V - 1200 • Engine Replace bearings if necessary and remove the clutch shaft. See also Removing the gearbox Removing the primary shaft • Remove the main shaft. • Operate on the main shaft from the second gear side. • 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.
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GRISO 8V - 1200 Engine • Remove the circlip. • Remove the gear of the third and fourth gears. • Remove the circlip and collect the shoulder washer. • Remove the gear of the fifth gear and collect the ball bearing cage.
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GRISO 8V - 1200 • Engine Heat the shaft with a specific heater and remove the helical transmission gear. Removing the secondary shaft • Remove the transmission shaft. • Operate on the shaft from the grooved side. • Remove the shoulder washer. • Remove the gear of the second gear and collect the ball bearing cage and the shoulder washer.
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GRISO 8V - 1200 Engine • Remove the circlip. • Remove the gear of the sixth gear. • Remove the circlip and collect the shoulder washer. • Remove the gear of the fourth gear and collect the ball bearing cage.
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GRISO 8V - 1200 • Engine Remove the gear of the third gear and collect the ball bearing cage and the shoulder washer. • Remove the circlip. • Remove the gear of the fifth gear. • Remove the circlip, the shoulder washer and remove the gear of the first gear, collect the ball bearing cage. • Remove the bearing if necessary.
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GRISO 8V - 1200 Engine Checking the primary shaft Measure coaxiality of the main shaft with a dial gauge and a centring device and replace it if not complying with specifications. Characteristic Shaft coaxiality limit 0.08 mm (0.0031 in) Check transmission gears for signs of pitting and wear and replace damaged gears if necessary. Check the gear fitting teeth for cracks, damage and wear and replace those damaged if necessary.
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GRISO 8V - 1200 Engine Checking the forks NOTE THE FOLLOWING PROCEDURE IS VALID FOR ALL TRANSMISSION FORKS. • Check the transmission fork cam roller «1» and the transmission fork tooth «2» for damage, deformation and wear. • Replace the transmission fork if necessary. • Check the transmission fork movement and if it is not regular, replace the transmission forks.
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GRISO 8V - 1200 Engine TO REFIT, FOLLOW THE SAME INSTRUCTIONS AS FOR REMOVAL BUT IN REVERSE ORDER. REMEMBER TO REPLACE ALL SEALING RINGS, CIRCLIPS AND SAFETY RINGS PREVIOUSLY REMOVED. If the clutch is replaced, measure the length of the clutch control rod in order to use the correct rod. Measure as follows: • Fit the new clutch on the crankshaft. • Fit the clutch control bowl in the gearbox. • Fit the gearbox on the engine block.
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GRISO 8V - 1200 Engine Generator Key: 1. Alternator 2. Spacer 3. Screw 4. Screw 5. Nut 6. Belt 7. Generator control pulley 8. Nut 9. Washer 10.Magneto flywheel cotter 11.Screw 12.
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GRISO 8V - 1200 Engine Removing the generator • Remove the fuel tank. • Remove the control unit from its seat. • Disconnect the alternator connectors. • Undo and remove the five screws and collect the bushings. • Remove the cover. • Unscrew the nut and collect the screw. • Loosen the screw.
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GRISO 8V - 1200 • Engine Loosen the nut and undo the set screw so that the alternator slides down. • Completely loosen and remove the screw. • Remove the belt and the alternator with pulley. • Using a compressed air gun, unscrew and remove the nut and collect the spacer. • Remove the lower pulley.
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GRISO 8V - 1200 Engine • Undo and remove the eight screws. • Undo and remove the two screws. • Undo and remove the two screws.
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GRISO 8V - 1200 • Remove the alternator frame. • Remove the sealing ring if necessary. Engine See also Fuel tank Tensioning the belt • Remove both fuel tank side fairings. • Remove the right exhaust manifold. • Remove the control unit. • Undo and remove the fixing screw of the engine oil scavenge reservoir. • 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.
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GRISO 8V - 1200 Engine • Using the belt tensioning tool, tension the belt to the prescribed torque. • Tighten the set screw. • Tighten the lock nut. Specific tooling 020677Y Alternator belt tensioner Installing the generator • If the sealing ring has been previously removed, replace it using the punch of the timing system cover sealing ring. Specific tooling 05.92.72.
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GRISO 8V - 1200 • Engine Place the bolt and the pin in the generator cover. • Replace the gasket and place the alternator frame using the front cover insertion 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. • Operating diagonally and in stages, tighten the ten fixing screws on the alternator fitting.
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GRISO 8V - 1200 Engine • Tighten the four screws, operating diagonally and in stages. • Position the lower pulley and the spacer. • Tighten the nut to the prescribed torque. • Position the alternator and the timing system belt. • Position the screw and pre-tighten it.
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GRISO 8V - 1200 • Position the screw and tighten the nut. • Using the belt tensioning tool, tension Engine the belt to the prescribed torque and tighten the set screw. • Remove the belt tensioning tool. • Lock the set screw in position by screwing the lock nut. Specific tooling 020677Y Alternator belt tensioner • Tighten the alternator fixing screws.
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GRISO 8V - 1200 Engine • Position the timing system cover. • Tighten the five screws, operating in oblique direction and in stages. Starter motor Removing the starter motor • Undo and remove the two screws and collect the washers. • Slide off the starter motor.
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GRISO 8V - 1200 Engine Clutch side Disassembling the clutch Key: 1. Complete clutch 2. Clutch 3. Clutch bell 4. TCEI screw 5. Clutch disc 6. Crown 7. TCEI screw 8. Clutch pressure plate 9. Ring 10.TE flanged screw 11.Conical washer 12.Bushing 13.Rod 14.Bushing 15.Intermediate body 16.Thrust bearing 17.
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GRISO 8V - 1200 Engine 18.Thrust cylinder 19.Clutch control cylinder 20.TE flanged screw • Remove the complete gearbox. • Undo and remove the six screws. • Remove the start-up crown gear. • Remove the clutch bell and the friction disc. • Remove the Seeger ring. • Remove the clutch pressure plate.
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GRISO 8V - 1200 • Engine Undo and remove the six screws and collect the belleville springs. • Remove the clutch disc. See also Removing the gearbox Checking the clutch actuator If the clutch is replaced, measure the length of the clutch control rod in order to use the correct rod. Measure as follows: • Fit the new clutch on the crankshaft. • Fit the clutch control bowl in the gearbox. • Fit the gearbox on the engine block.
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GRISO 8V - 1200 Engine 020678Y Tool for clutch rod checking CLUTCH CONTROL ROD SELECTION Specification Protrusion: 9.8 - 11.2 mm (0.386 - 0.441 in) Protrusion: 8.3 - 9.7 mm (0.327 - 0.382 in) Protrusion: 6.8 - 8.2 mm (0.268 - 0.323 in) Protrusion: 5.3 - 6.7 mm (0.209 - 0.264 in) Desc./Quantity Clutch control rod length (code 976593) = 183 mm (7.205 in) Clutch control rod length (code 976594) = 184.5 mm (7.264 in) Clutch control rod length (code 976595) = 186 mm (7.
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GRISO 8V - 1200 • Engine Once the centring tool is fitted, lock the plate with the snap ring. • Undo and remove the two screws fixing the tool. • Remove the special tool. • Place the friction disc; centre it. • Place the clutch bell with the reference facing upwards. • Place the start-up crown gear with the reference facing upwards. • Tighten the six screws to the prescribed torque operating diagonally and in stages.
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GRISO 8V - 1200 Engine Head and timing Key: 1. Right cylinder head 2. Stud bolt 3. Cylinder head gasket 4. Right rocking lever support 5. Screw 6. Pin 7. Nut 8. Right exhaust, left intake rocking lever 9. Left exhaust, right intake rocking lever 10.Set screw 11.Nut 12.Rocking lever rod 13.Tappet bowl 14.Flanged screw 15.Spacer 16.Camshaft 17.Pin 18.Timing system gear 19.
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GRISO 8V - 1200 Engine 20.TE flanged screw 21.O-ring 22.Complete breather cover 23.TBEI screw 24.Timing system chain 25.Chain guide slider 26.Chain tensioner pad 27.Chain tensioner screw 28.Right chain tensioner 29.Left cylinder head 30.Stud bolt 31.Cylinder head gasket 32.Left rocking lever support 33.Screw 34.Pin 35.Nut 36.Right exhaust, left intake rocking lever 37.Left exhaust, right intake rocking lever 38.Set screw 39.Nut 40.Rocking lever rod 41.Tappet bowl 42.Flanged screw 43.Spacer 44.Camshaft 45.
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GRISO 8V - 1200 Engine Removing the head cover NOTE THE OPERATIONS DESCRIBED BELOW REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH HEADS. • Disconnect the spark plug tube. • Undo and remove the four head cover fixing screws and collect the sealing Orings. • Remove the head cover together with the gasket. Removing the cylinder head CAUTION WHEN REMOVING THE COMPONENTS, MARK THE POSITION OF EACH PART VERY CAREFULLY IN ORDER TO PLACE THEM IN THEIR ORIGINAL POSITION UPON FITTING.
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GRISO 8V - 1200 • Undo and remove the screw. • Remove the timing system upper gear Engine bulkhead. For the right head: • Unscrew and remove the chain tensioner cap. • Remove the right chain tensioner. For the left head: • Undo and remove the screw and the washer. • Relief oil pressure from the left chain tensioner.
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GRISO 8V - 1200 Engine • Slide off the timing system gear from the chain to remove it from the camshaft. • Unscrew and remove the four nuts on the stud bolts. • Remove the complete cam cap. • Undo and remove the two screws. • Remove the head. • Fit the timing system upper gear back to the chain. • Fit the chain tensioner cap temporarily and keep the chain taut on the service shaft.
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GRISO 8V - 1200 • Collect the two head dowel pins. • Collect the gasket between the head Engine and the cylinder. See also Removing the head cover Cylinder head Removing the overhead camshaft CAUTION WHEN REMOVING THE COMPONENTS, MARK THE POSITION OF EACH PART VERY CAREFULLY IN ORDER TO PLACE THEM IN THEIR ORIGINAL POSITION UPON FITTING. • Remove the two rocking levers from the cam cap. • Remove the two rods. • Undo and remove the four screws. • Remove the U-bolt.
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GRISO 8V - 1200 Engine • Remove the camshaft. • Remove the bowls from the cam cap, and mark their position so as not interchange them when refitting. See also Removing the rocker arms Removing the rocker arms CAUTION WHEN REMOVING THE COMPONENTS, MARK THE POSITION OF EACH PART VERY CAREFULLY IN ORDER TO PLACE THEM IN THEIR ORIGINAL POSITION UPON FITTING. • Remove the cam cap from the stud bolts. • Undo and remove the two screws. • Remove the U-bolt.
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GRISO 8V - 1200 • Engine Remove the two rocking levers from the cam cap. See also Removing the cylinder head Removing the valves • Remove the head. • Place the special tool on the upper cap and at the centre of the head of the valve to be removed. Specific tooling 10.90.72.
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GRISO 8V - 1200 Engine The valve guides should be replaced only if the clearance between them and the stem cannot be eliminated by simply replacing the valves. To refit the valve guides on the head, follow this procedure: • Heat the head in an oven at about 60°C (140°F). • Lubricate the valve guide. • Fit the circlips. • Press the valve guide with a punch. • Use a reamer to bore the holes the valve stems slide through so that the inside diameter is at the prescribed value.
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GRISO 8V - 1200 Engine OUTLET VALVE SEAT DETAIL DRAWING - If the width of the mark on the valve seat is larger than the prescribed limits, true the seats with a 45° milling cutter and then grind. - Replace the head in case of excessive wear or damage. Installing the valves NOTE THE FOLLOWING OPERATIONS REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH HEADS. • Place the valve guide oil seal (4) in the head. • Place the lower cap (5). • Place the valve (6) inside the head. • Place the spring (3).
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GRISO 8V - 1200 Engine Installing the rocker arms • Fit the camshaft. • Fit the two rods. • Place the two rocking levers in the cam cap seats. • Place the U-bolt on the rocking levers making sure the two reference pins match the seats on the cam cap. • Tighten the two screws operating diagonally and in stages.
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GRISO 8V - 1200 Engine Installing the overhead camshaft • Place the bowls in the cam cap, if those previously removed are refitted be careful not to interchange them. • Place the camshaft with the gear seat on the dowel side. • Place the U-bolt on the camshaft making sure the two reference pins match the seats on the cam cap. • Tighten the four screws operating diagonally and in stages.
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GRISO 8V - 1200 Engine Removing the phonic wheel • Remove the generator and the timing system cover. • Unscrew and remove the nut and collect the washer. • Remove the timing system gear on the service shaft. • Remove the timing sensor and any shim washers. • Remove the tone wheel. • Remove the cotter and shim washer from the service shaft. See also Removing the generator Service shaft removal • Remove the tone wheel. • Remove both cylinders. • Undo and remove the two screws.
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GRISO 8V - 1200 • Engine Mark the timing chains so as not to invert the direction of rotation upon fitting. • Slide off the service shaft from the chains. • Remove both chains. See also Removing the phonic wheel Installing the service shaft • Place the service shaft bearing (if previously removed) on the crankcase. • Fix it to the seat with the lock washer and screw. • Fit the timing chains according to the references marked at the removal phase. • Lubricate the service shaft.
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GRISO 8V - 1200 Engine • Partially fit the service shaft closing cap. • To screw the cap until it stops, use two M6 flanged screws larger than the original screws. • Tighten the two M6 flanged screws operating in stages until the cap stops against the crankcase. • Undo and remove the two M6 flanged screws. • Tighten the cap with the two original TBEI screws. Installing sliders • Fit the crankshaft and the service shaft on the crankcase.
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GRISO 8V - 1200 Engine Cam timing • Fit the crankshaft and the service shaft on the crankcase. • Fit the cylinders. • Turn the crankshaft until the left cylinder piston reaches the top dead centre (TDC). • Fit the cotter and the shim washer on the service shaft. • Fit the tone wheel with the chamfered side facing the crankcase on the service shaft. • Lock crankshaft rotation. • Unscrew and remove the nut fixing the crankshaft gear. • Remove the oil pump control gear. Specific tooling 12.
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GRISO 8V - 1200 Engine • After shimming the timing sensor properly, proceed to fit it. • Fit the washer and tighten the timing system gear fixing nut of the service shaft. • Place a new gasket between the crankcase and the oil pump. • Place the oil pump. • Tighten the three screws fixing the oil pump. • Place the driving pin on the oil pump shaft.
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GRISO 8V - 1200 • Place the gear on the oil pump shaft. • Place the washer on the oil pump shaft. • Tighten the nut to the specified torque. • Place the oil pump control gear on the Engine crankshaft and align its reference with that marked during the removal phase on the oil pump driven gear. • Tighten the nut to the specified torque. • Tighten the screw with the washer to the prescribed torque.
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GRISO 8V - 1200 Engine Measuring air gap • Undo and remove the two screws and remove the sensor. • Insert a suitable plain washer on the sensor and note its thickness. • Place the sensor on the crankcase and move it until it makes contact with the tone wheel. • Measure the clearance between the fixing plate and the crankcase with a thickness gauge. Subtract the plain washer value from this measurement to obtain the clearance between the sensor and the tone wheel.
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GRISO 8V - 1200 Engine Cylinder-piston assembly Key: 1. Right cylinder 2. Piston 3. Screw 4. Top piston ring 5. Middle piston ring 6. Oil scraper piston ring 7. Pin 8. Snap ring 9. Cylinder base gasket 10.Stud bolt 11.Pin 12.Cylinder head gasket 13.Left cylinder 14.Washer 15.Chain tensioner cap 16.Washer 17.Left chain tensioner 18.
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GRISO 8V - 1200 Engine Removing the cylinder NOTE THE OPERATIONS DESCRIBED BELOW REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH HEADS. • Remove the head, the gasket between the head and the cylinder and the two dowel pins. • Slide off the movable chain slider. • Remove the cylinder from the stud bolts. • Remove the two dowel pins on the stud bolts. • Remove the two gaskets between the crankcase and the cylinder. • Cover the crankcase opening with a clean cloth.
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GRISO 8V - 1200 • Engine Mark the piston crown on the outlet side to remember its position when refitting. • Remove the piston. Fitting the piston NOTE THE OPERATIONS DESCRIBED BELOW REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH HEADS. • The reference on the piston ring must be facing the piston crown. • Fit the piston rings on the piston: - the oil scraper in the lower slot; - the thicker smooth ring in the intermediate slot; the less thick smooth ring in the upper slot.
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GRISO 8V - 1200 Engine • Insert the pin. • Insert the snap ring. Specific tooling 020470Y Pin snap ring fitting tool Installing the cylinder RIGHT CYLINDER • Fit the piston. • Remove the cloth used to prevent foreign bodies from getting into the crankcase. • Turn the rings so that the coupling ends are 120 degrees from each other. • Place a new metal gasket between the crankcase and the cylinder. Place the two dowel pins on the stud bolts. Lubricate the piston and the cylinder.
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GRISO 8V - 1200 Engine 020716Y Connecting rod locking • Remove the piston ring clamp tool and finish positioning the cylinder. Specific tooling 020674Y Piston ring clamp • Fit the movable chain slider. • Fit the upper gear. • Fit the chain tensioner and the chain tensioner cap temporarily and keep the chain taut on the service shaft. LEFT CYLINDER • Fit the piston. • Remove the cloth used to prevent foreign bodies from getting into the crankcase.
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GRISO 8V - 1200 Engine • Check that the oil in the left cylinder chain tensioner has been drained off by compressing it. If the operation is difficult, use a pin drive to push the central hole so that the oil is drained off from the circuit. • Fit the chain tensioner in the cylinder. • Lubricate the piston and the cylinder. • Lock connecting rod motion with the fork tool. • Using the suitable piston ring clamp tool, place the cylinder and fit the chain in the timing system plate.
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GRISO 8V - 1200 Engine Installing the cylinder head • Fit the valves in the head, if previously removed. • Take the left cylinder piston to TDC and lock crankshaft rotation. • Determine the thickness of the gasket to be fitted between the head and the cylinder as described in the section: Shimming system. • Place the two dowel pins. • Fit the gasket with the correct thickness between the head and the cylinder. • Fit the left cylinder head. • Fit a new O-ring in the spark plug hole.
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GRISO 8V - 1200 Engine • Fix the head with the two screws. • Tighten nuts and screws to the prescribed torque operating diagonally and in stages. • Loosen the valve set screws. • Using a thin screwdriver relief oil pressure from the left cylinder chain tensioner. • Screw two screws in the threaded holes of the timing system upper gear. • Place the gear in the chain. • On the left camshaft pin, fit the hole marked with the letter "L" of the timing system gear.
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GRISO 8V - 1200 • Engine Fit the gasket with the correct thickness between the head and the cylinder. • Fit the right cylinder head. • Unscrew and remove the right chain tensioner cap. • Screw two screws in the threaded holes of the timing system upper gear. • Place the gear in the chain. • On the right camshaft pin, fit the hole marked with the letter "R" of the timing system gear. • Screw the cap of the right chain tensioner.
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GRISO 8V - 1200 Engine • Place the cap. • Tighten the two screws to the prescribed torque. • Also place the cap of the other head. • Adjust valve clearance. See also Checking the valve clearance Installing the head cover • Replace the gasket and install the head cover. • Place the plastic half-cover. • Replace the four rubber rings. • Tighten the four screws to the prescribed torque. • Place the spark plug tube.
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GRISO 8V - 1200 Engine Crankcase - crankshaft Removing the crankshaft • Remove the clutch. • Remove the tone wheel and the oil pump gear. • Working from the generator side, unscrew and remove the nut. • Remove both gears. • Remove the connecting rods. • Undo and remove the eight fixing screws and collect the washers. • Hold the crankshaft during flange removal. • Using the suitable special tool, remove the crankshaft flange. • Remove the sealing ring from the flange, if necessary.
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GRISO 8V - 1200 Engine • Remove the crankshaft afterwards. • Collect the shim washer from inside the crankcase. See also Disassembling the clutch Removing the phonic wheel Disassembling the connecting rod • Remove both heads. • Remove the cylinders and the pistons. • Remove the oil sump. • Undo the coupling screws (A) inside the crankcase and remove the connecting rods (B).
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GRISO 8V - 1200 Engine Inspecting the crankshaft components Check the surfaces of the main journals; if they are scored or oval-shaped, reface them (observing the undersize charts), and replace the main bushing/ s. Reference (1) indicates the position where the coloured reference is applied to select diameter (B). Reference (2) indicates the position where the coloured reference is applied to select balancing.
PAGE 158
GRISO 8V - 1200 Engine Upon replacing the bearings it may be necessary to ream the crankshaft pin. Before reaming the crankpin, measure the pin diameter (B) comparing it with the maximum wear allowed, as indicated in the figure; this defines what kind of undersizing the bearing should have and to which diameter the pin (B) should be reamed. Checking shaft parallelism Check shafts for squaring before fitting them.
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GRISO 8V - 1200 Engine The connecting rods have a marked area for weight selection. The weight indicated in the chart includes screws, dowels and the bushing. CONNECTING ROD WEIGHT SELECTION Specification Connecting rod - brown Connecting rod - green Connecting rod - black Desc./Quantity 0.588 - 0.598 mm (0.02074 - 0.02109 in) 0.598 - 0.608 mm (0.02109 - 0.02145 in) 0.608 - 0.618 mm (0.02145 - 0.
PAGE 160
GRISO 8V - 1200 Engine PAY ATTENTION TO CRANKSHAFT ROTATION WHEN ONLY THE CONNECTING RODS ARE FITTED BECAUSE IT COULD HIT THE TWO LUBRICATION JETS INSIDE THE CRANKCASE. Installing the crankshaft • Fit the shim washer inside the crankcase with the chamfered side facing the generator side. • Lubricate the crankshaft bushing on the crankcase, generator side. • Use the sealing ring fitting tool on the flywheel-side flange to fit the sealing ring on the flange. Specific tooling 19.92.71.
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GRISO 8V - 1200 • Engine Place the flywheel-side flange on the crankshaft and check if the dowel pin with the O-ring is correctly placed. • When fitting the flange on the crankcase, make sure that the three dowel pins match the seats on the crankcase. • Apply Teflon tape on the two lower fixing screws at the back in order to prevent oil leaks. • Screw the eight flange screws on the flywheel side proceeding diagonally. • Remove the sealing ring centring tool from the crankshaft.
PAGE 162
GRISO 8V - 1200 Engine Refitting the crankcase halves In case the lubrication jets are removed, replace them with two new of the same type. Check that the O-ring is fitted on the jets. Do not interchange them upon refitting because they have a different length.
PAGE 163
GRISO 8V - 1200 Engine 1. Oil radiator 2. Oil delivery pipe to heads 3. Oil delivery pipe to radiator 4. Oil pump body 5. Oil pump gasket 6. Rotor for lubrication 7. Rotor for cooling 8. Rotor control shaft 9. Oil pump cover 10.Oil pump control gear 11.Lubrication oil intake filter 12.Cooling oil intake filter The oil pump is operated by the gear (10) which receives the motion directly from the crankshaft.
PAGE 164
GRISO 8V - 1200 Engine • Remove the nipple - oil pump fitting. • Bring the left cylinder piston to the TDC in combustion phase. • Mark a reference on the oil pump control gear and another on the driven gear so as to place them correctly again upon refitting. • Unscrew and remove the nut on the crankshaft. • Remove the oil pump control gear. • Screw the nut again so that the internal shim washer does not fall in the crankshaft crankcase. • Unscrew and remove the driven gear nut.
PAGE 165
GRISO 8V - 1200 • Undo and remove the three screws. • Remove the oil pump. • Remove the gasket between the Engine crankcase and the oil pump. See also Replacement Removing the generator Installing • Place a new gasket between the crankcase and the oil pump. • Place the oil pump. • Tighten the three screws fixing the oil pump.
PAGE 166
GRISO 8V - 1200 Engine • Place the driving pin on the oil pump shaft. • Place the gear on the oil pump shaft. • Place the washer on the oil pump shaft. • Tighten the nut to the specified torque. • Place the oil pump control gear on the crankshaft and align its reference with that marked during the removal phase on the oil pump driven gear. • Tighten the nut to the specified torque.
PAGE 167
GRISO 8V - 1200 • Insert the joint in the oil pump. • Fit the nipple with the gasket on the Engine crankcase. • Tighten the nipple to the prescribed torque. Removing the oil sump NOTE TO REMOVE THE OIL SUMP, PLACE A SUITABLE CONTAINER UNDER IT TO COLLECT THE USED OIL AND DRAIN OUT ALL OIL. • If necessary, the filter can be removed with the suitable special tool. Specific tooling 01.92.91.
PAGE 168
GRISO 8V - 1200 Engine • Undo and remove the fourteen screws fixing the oil sump to the engine crankcase. • Undo and remove the four screws. • Remove the flange.
PAGE 169
GRISO 8V - 1200 • Undo and remove the two screws. • Remove both filters. • Unscrew and remove the plug. • Remove the thermostatic valve. • Unscrew and remove the pressure re- Engine lief valve plug.
PAGE 170
GRISO 8V - 1200 Engine Refitting the oil sump • Place the pressure relief valve components correctly. • Screw the pressure relief valve plug. • Place the thermostatic valve. CHECK THAT THE ENGINE OIL PASSAGE HOLE IS NOT CLOGGED.
PAGE 171
GRISO 8V - 1200 • Tighten the thermostatic valve plug. • Place a new gasket between the crank- Engine case and the flange. • Fit the flange. • Fix the flange with the four screws. • Fit the lubrication oil intake filter.
PAGE 172
GRISO 8V - 1200 Engine • Check that the O-rings are fitted on the oil pump. • Fit the cooling oil intake filter. • Fix both filters and tighten the two screws to the prescribed torque. • Fit a new oil filter and tighten it to the prescribed torque. • Place a new gasket between the flange and the sump.
PAGE 173
GRISO 8V - 1200 • Place the oil sump. • Tighten the fourteen screws to the pre- Engine scribed torque. • Add engine oil up to the correct level. Blow-by The figure illustrates the correct position for the fastening clamps of the pipes on the blow-by tank. Both blow-by and clutch pipes should be laid, in the front part of the chassis, underneath the main cable harness. Fuel pipes in the area underneath the fuel tank should be laid over the (grey) blow-by pipes.
PAGE 174
GRISO 8V - 1200 Engine Blow-by pipes laying on the right-hand size of the vehicle. Blow-by pipes laying on the left-hand size of the vehicle.
PAGE 175
INDEX OF TOPICS POWER SUPPLY Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten P SUPP
PAGE 176
GRISO 8V - 1200 Power supply Circuit diagram Key: 1. Complete fuel pump unit 2. Screw 3. Fuel pipe 4. Pipe 5. Screw FUEL PIPES LAYING The fuel pipes should be laid in the innermost position compared to the electrical connections.
PAGE 177
GRISO 8V - 1200 Power supply The shortest part of the fuel pipe connected to the throttle bodies should be placed on the right. Fuel pipes in the area underneath the fuel tank should be laid over the (grey) blow-by pipes.
PAGE 178
GRISO 8V - 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 179
GRISO 8V - 1200 Power supply 13 Lambda probe 14 Fall sensor THROTTLE BODY PIPES LAYING Pipes from the throttle body to the idle motor should be laid so that the shaped part is inserted in the air filter casing. The shortest part of the fuel pipe connected to the throttle bodies should be placed on the right. Cylinders synchronisation • With engine off, connect the Axone 2000 tool to the diagnosis connector and to the vehicle battery. • Turn on the scanner.
PAGE 180
GRISO 8V - 1200 Power supply • Make sure there are no errors in the control unit; otherwise, solve them and repeat the procedure. • Make sure the left throttle is fully in. DO NOT TOUCH THE THROTTLE ABUTMENT SCREW OR THE THROTTLE BODY MUST BE REPLACED. CHECK THAT THE THROTTLE RETURN CABLE IS NOT TAUT. • The Axone should display the adjustable parameters screen page. • Autodetect the throttle position. • Turn the key to "OFF" and leave it for at least 30 seconds.
PAGE 181
GRISO 8V - 1200 Power supply If there is a larger difference: • act on the set screw of the throttle body connecting rod to reduce the pressure difference in the two pipes. • Repeat the procedure "Throttle position self-learning" as explained above. • Bring the engine back to idle and check the depression values so that they are aligned between the two cylinders. • Otherwise, open only the screw with higher depression, using the by-pass screws, to compensate.
PAGE 182
GRISO 8V - 1200 Power supply Iso screen page ISO This display shows general data regarding the control unit, for example software type, mapping, control unit programming date ISO DISPLAY Specification Mapping Desc./Quantity - Engine parameter reading screen page ENGINE PARAMETER READING This display shows the parameters measured by the several sensors (engine revs, engine temperature, etc.) or values set by the control unit (injection time, ignition advance, etc.
PAGE 183
GRISO 8V - 1200 Power supply Specification Target engine revs Desc./Quantity 1150 rpm (approximate values) Parameter valid at idle, setting depends especially on the engine temperature: the control unit will try to keep the engine running at this revs, acting on the ignition advance and the Stepper motor 70 - 100 (approximate values) Steps corresponding to the Stepper motor reference position 70 - 150 (approximate values) Steps set by the control unit for the Stepper motor.
PAGE 184
GRISO 8V - 1200 Power supply Devices activation screen page DEVICES ACTIVATION This displays is used to delete errors in the control unit memory and activate some systems controlled by the control unit DEVICES ACTIVATION Specification Left coil Right coil Left injector Right injector Error clearing Desc./Quantity operation for 2.5 m, 5 times operation for 2.
PAGE 185
GRISO 8V - 1200 Power supply Specification Right injector Fuel pump relay Left coil Right coil Idle regulator Battery voltage Starter diagnosis Engine revolution sensor Lambda heater SPEED SENSOR CAN line diagnosis RAM memory ROM memory Microprocessor Checksum EPROM Desc./Quantity Possible short circuit in the earth lead, battery or open circuit. If both injectors do not work, the engine does not work Possible short circuit in the earth lead, battery or open circuit: the engine does not start.
PAGE 186
INDEX OF TOPICS SUSPENSIONS Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten SUSP
PAGE 187
GRISO 8V - 1200 Suspensions Front Removing the front wheel • Working from both sides, undo and remove the two fixing screws from the front brake callipers and remove them from their seats. • Support the front part of the vehicle. • Unscrew and remove the nut fixing the wheel bolt and collect the sealing ring. • Working from both sides, loosen the screws on the wheel bolt clamps. • Hit the wheel pin slightly with a rubber hammer so that the hole on the opposite side is exposed.
PAGE 188
GRISO 8V - 1200 Suspensions • Take out the wheel bolt by inserting a screwdriver in the bolt holes. • Upon extracting the wheel, hold it and then remove it. • Collect the spacer from the front wheel right side.
PAGE 189
GRISO 8V - 1200 Suspensions 1. Radial fork right stem 2. Radial fork left stem 3. Sleeve 4. Pumping member attachment bushing 5. Spring 6. Complete preloading pipe 7. Spacer 8. Washer 9. Complete pumping element 10.Washer 11.Ring 12.Complete sleeve cap 13.O-ring 14.O-ring 15.O-ring 16.Snap ring 17.TE flanged screw M8x40 18.Stem + right wheel holder 19.Stem + left wheel holder 20.Dust guard 21.Seeger ring 22.Oil seal 23.Ring 24.Bushing 25.Sliding bushing 26.Special washer 27.screws M10x1.
PAGE 190
GRISO 8V - 1200 Suspensions FOR ADJUSTMENT, ALWAYS START FROM THE MOST RIGID SETTING (SET SCREWS (1 - 2) FULLY CLOCKWISE). USE THE NOTCHES ON SET SCREWS (1 - 2) AS REFERENCES TO ADJUST HYDRAULIC COMPRESSION AND REBOUND DAMPING. TURN THE SET SCREWS (1 - 2) GRADUALLY BY 1/8 OF A TURN AT A TIME. FRONT FORK ADJUSTMENT Specification Desc./Quantity Standard rebound damping adjustment, screw (1) open (**) 1,5 click from fully closed (*) Hydraulic rebound damping adjustment for sports use, screw Open (**) 0.
PAGE 191
GRISO 8V - 1200 Suspensions See also Removing the front wheel Draining oil • Lock the sleeve in a vice with the specific tool (code AP8140149). • Set the minimum spring preloading. Specific tooling AP8140149 Protection for fitting operations • Unscrew the sleeve upper cap. • Lock the fork end in a vice paying attention not to damage it. • Fit the tool on the spring joint.
PAGE 192
GRISO 8V - 1200 Suspensions • Push the tool against the spring and compress it. Fit the spacer of the tool under the cartridge lock nut. Specific tooling AP8140148 Spacer-pumping element separating plate • Loosen the cap acting on the wrench slot and making the lock nut turn. • Remove the whole cap. • Detach the spacer and the washer. • Press down the spring and slide off the spacer.
PAGE 193
GRISO 8V - 1200 • Slide off the spring joint. • Empty the oil into a container and re- Suspensions move the spring. Disassembling the fork • After emptying the oil, fasten the fork stem end in a vice. • Take out the washer and the lower spacer.
PAGE 194
GRISO 8V - 1200 Suspensions • Undo the screw fixing the cartridge on the fork end. • Collect the centring bushing. • Slide off the dust scraper from the sleeve using a screwdriver as a lever. • Do not damage the sleeve edge while doing this. • Remove the snap ring.
PAGE 195
GRISO 8V - 1200 • Suspensions Take out the sleeve from the stem using the stem as a hammer puller. • From the stem remove the fixed fitted bushing, the movable bushing, the ring and the oil seal.
PAGE 196
GRISO 8V - 1200 Suspensions • Remove the ring and the dust guard. See also Draining oil Checking the components Stem Check the sliding surface for scorings and/or scratches. These scorings can be eliminated by rubbing them with wet sandpaper (grain 1). If the scorings are deep, replace the stem. Use a dial gauge to check that the stem bending is below the limit value. If over the value, replace the stem.
PAGE 197
GRISO 8V - 1200 Suspensions Check that the following components are in good conditions: • sliding bushing; • guide bushing; • pumping member. If there are signs of excessive wear or damage, replace the affected component. CAUTION REMOVE ANY IMPURITY IN THE BUSHINGS, TAKING CARE NOT TO SCRATCH THEIR SURFACE. Replace the following components with new ones: • gasket; • dust guard gasket; • the two O-rings on the regulator.
PAGE 198
GRISO 8V - 1200 Suspensions Reassembling the fork • Lock the stem in a vice without damaging the surfaces. • Protect the bearing tube end with adhesive tape. • Lubricate the sliding edges with fork oil or with seal grease. • Fit the dust scraper, the snap ring and the sealing ring on the slider. • The sealing ring must be placed with the stamped part facing the dust guard.
PAGE 199
GRISO 8V - 1200 • Suspensions Fit the ring, the movable bushing and, after removing the tape, fit the fixed bushing. • Fit the sleeve on the stem and with the specified tool fit the oil seal into position. Specific tooling AP8140189 Oil seal fitting tool for Ø 43 mm (1.69 in) holes 8140145 Fitting tool for Ø 41 mm (1.
PAGE 200
GRISO 8V - 1200 Suspensions • Insert the snap ring in its position. • Fit the oil seal with the specific tool. Specific tooling AP8140189 Oil seal fitting tool for Ø 43 mm (1.69 in) holes 8140145 Fitting tool for Ø 41 mm (1.61 in) sealing ring 8140146 Weight to be applied to the tool: 8140145 and 8140189 • Fit the centring bushing on the cartridge and insert the whole assembly in the fork. • Tighten the screw fixing the pumping element on the fork end to the prescribed torque.
PAGE 201
GRISO 8V - 1200 • Suspensions Position the lower spacer and the washer. Filling oil • Place the sleeve upright in a vice fitted with protection shoes. • Compress the sleeve in the stem. • Pour part of the fork oil into the sleeve. • Wait for some minutes until the oil fills all the ducts. • Pour the oil left. • Pump out oil a few times. • Measure the air gap between the oil level and the rim. THE SLEEVE MUST BE PERFECTLY UPRIGHT FOR A CORRECT OIL LEVEL MEASUREMENT.
PAGE 202
GRISO 8V - 1200 Suspensions • Fit the spring. • Fit the complete preloading pipe. • Fit the specified tool on the spring coupling so that the cartridge stem is locked in position. Specific tooling 8140147 Spacer tool 8140148 Spacer / pumping member separating plate • Position the spacer and the washer.
PAGE 203
GRISO 8V - 1200 • Suspensions Screw the upper cover on the cartridge stem. • Place the sleeve in the vice using the specified tool. • Screw the upper cap to the prescribed torque.
PAGE 204
GRISO 8V - 1200 Suspensions Adjusting play • Undo and remove the two front screws. • Undo and remove the two external screws and move the instrument panel forwards. • Undo and remove the screws and collect the U-bolts, holding the handlebar. • Move the handlebar forward without tilting the clutch and the front brake fluid reservoirs. • Undo and remove the screw. • Collect the right handlebar support.
PAGE 205
GRISO 8V - 1200 • Suspensions Unscrew and remove the fork upper plate cover; collect the shim. • Working on both sides, undo and remove the upper plate fixing screw on the fork stems. • Lift the fork upper plate sliding it off from the stems. • Rivet the safety washer on the headstock. UPON REFITTING, REPLACE THE SAFETY WASHER WITH A NEW ONE.
PAGE 206
GRISO 8V - 1200 Suspensions • Using the suitable special tool, unscrew and remove the upper ring nut. Specific tooling AP8140190 Tool for steering tightening • Remove the safety washer. • Using the suitable special tool, set the preloading of the steering bearings. Specific tooling AP8140190 Tool for steering tightening • Fit a new safety washer.
PAGE 207
GRISO 8V - 1200 • Suspensions Screw the upper ring nut manually and then slightly tighten the clamps on the plate so as to align notches on the ring nut. Specific tooling AP8140190 Tool for steering tightening • Rivet the tongues of the new safety washer. • Fit the fork upper plate on the stems. Rear Removing the rear wheel • Support the vehicle from the rear with an adequate stand. • Remove the cover.
PAGE 208
GRISO 8V - 1200 Suspensions • Engage the first gear. • Undo and remove the four screws, collect the spacers and the dust-protection ring. • Remove rear wheel. Shock absorbers Adjusting The rear suspension consists of a spring-shock absorber unit linked to the frame via silent-block and to the rear fork via a linkage system.
PAGE 209
GRISO 8V - 1200 Suspensions However, this set can be modified for specific needs according to vehicle use. ALLOW ENGINE AND EXHAUST SILENCER TO COOL OFF BEFORE OPERATING THE SET SCREWS. NOTE TO COUNT THE NUMBER OF CLICKS AND/OR TURNS OF THE SET SCREWS (1-2) ALWAYS START FROM THE MOST RIGID SETTING (SET SCREW FULLY CLOCKWISE). USE THE SET SCREWS (1-2) AS REFERENCES FOR ADJUSTING THE HYDRAULIC COMPRESSION / REBOUND DAMPING. GRADUALLY TURN THE SET SCREWS (1 -2) ONE NOTCH AT A TIME.
PAGE 210
GRISO 8V - 1200 Suspensions • Support the vehicle from below with a suitable underpan jack. • Support the vehicle from the front with a suitable stand. • Unscrew and remove the fixing nut. • Take out the screw tapping lightly with a rubber hammer and follow as the assembly slides out of its position.
PAGE 211
GRISO 8V - 1200 • Suspensions Undo and remove the suspension lower screw. • Undo and remove the suspension upper screw.
PAGE 212
INDEX OF TOPICS CHASSIS Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten CHAS
PAGE 213
GRISO 8V - 1200 Chassis Swinging arm Removing • To remove the fork, first remove both footrest supporting plates and the exhaust silencer. • Slide off the rear brake calliper from the disc and release the brake pipe. • Remove the cover. • Engage first gear. • Undo and remove the four screws, collect the spacers and the dust-protection ring. • Remove the rear wheel. • Unscrew and remove the nut fixing the reaction rod. • Remove the screw.
PAGE 214
GRISO 8V - 1200 Chassis • Remove the clamp from the dust guard cap. • Loosen the two fork terminal screws. • Unscrew and remove the fixing nut of the connecting rod assembly and collect the screw. • Disconnect the speed sensor connector and release the cable from the clamp on the chassis.
PAGE 215
GRISO 8V - 1200 • Chassis 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. 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 216
GRISO 8V - 1200 Chassis Installing • Spread a thin layer of lubricating grease all along the fork pin. • Fit the ring nut in the fork pin and screw it manually. • Working from both sides, grease the cardan shaft cables with the recommended product from the recommended products table. • Block the fork, insert the universal joint, align the holes and, at the same time, helped by a second operator, insert the pin completely. • Tighten the fork pin.
PAGE 217
GRISO 8V - 1200 • Fit the dust guard cap in the gearbox. • Lock the dust guard cap with a new Chassis clamp. • Place the reaction rod into its seat. • Insert the screw. • Screw the nut fixing the reaction rod. • Place the connecting rod assembly on the fork. • Insert the screw. • Tighten the fixing nut of the connecting rod assembly. • Connect the speed sensor connector and fix the cable to the chassis with clamps.
PAGE 218
GRISO 8V - 1200 Chassis • Place the rear wheel on the fork. • Tighten the four screws with their spacers and the dust-protection ring. • Place the cover. • Place the rear brake calliper on the disc and the brake pipe on the fork. See also Recommended products chart Bevel gears Removing • To remove the gearbox, first remove the exhaust silencer and the rear wheel. • Unscrew and remove the nut fixing the reaction rod. • Remove the screw. • Fasten the reaction rod to the chassis with a clamp.
PAGE 219
GRISO 8V - 1200 • Undo and remove the four screws. • Remove the transmission casing slid- Chassis ing off the universal joint.
PAGE 220
GRISO 8V - 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 screwdriver. Remove the stop rings (3) and (6) from the support (5) with suitable pliers. NOTE THIS OPERATION DESTROYS THE SEALING RING. 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.
PAGE 221
GRISO 8V - 1200 Chassis Turn the support (5) over. Assemble the ball joint (4) with the buffer and a rubber hammer. Fit the stop ring (3) in the support (5) with suitable pliers. Manually assemble the new sealing rings (2) and (7). Assemble the bushing (1). Drive the bushing (1) in with a plastic hammer. Turn the support (5) over and assemble the other bushing (8).
PAGE 222
GRISO 8V - 1200 Chassis REMOVAL Remove the stop ring (1) from the ring nut. Unscrew the ring nut (2) with the special spanner (s4). Remove the ring nut (2) and remove the sealing ring from the ring nut. NOTE THIS OPERATION DESTROYS THE SEALING RING. Assemble the sealing ring (3) to the ring nut (2) with the buffer CA715855 (see Fig.1) and a hammer.
PAGE 223
GRISO 8V - 1200 Chassis Lubricate the sealing ring (3). Assemble the ring nut (2). Tighten the ring nut (2) with the special spanner (s4) to the prescribe torque. Insert the stop ring (1) in the ring nut (2) in the indicated direction.
PAGE 224
GRISO 8V - 1200 Chassis Assembly position of the stop ring (1). CAUTION MAKE SURE THE STOP RING IS IN ITS SEAT. 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 225
GRISO 8V - 1200 Chassis Heat the casing. Insert the support group in the casing. Assemble the cap and the ring. Fit the cap on the support. Fit the clamp.
PAGE 226
GRISO 8V - 1200 Chassis Screw the clamp with the specific pliers. Apply the prescribed sealant to the casing. Fit a new sealing ring using the buffer. Lubricate the sealing ring. Assemble two centring stud bolts with M8 thread in the threaded holes of the casing as shown in the picture.
PAGE 227
GRISO 8V - 1200 Chassis Fit the casing. Remove the two dowel pins. Assemble the fixing screws (7). Tighten the screws (7) to the prescribed torque. Remove excessive sealant. Assemble the ring to the casing. Tighten the fixing screws to the prescribed torque.
PAGE 228
GRISO 8V - 1200 Chassis Fit the cap with the washer. Screw the cap to the prescribed torque. Fit the breather with the washer. Screw the breather to the prescribed torque. Fill the transmission with the prescribed oil. Fit the cap with the washer. Screw the cap to the prescribed torque. Assemble the cap with the clamps.
PAGE 229
GRISO 8V - 1200 Chassis Fit the cap in its seat. Wheel axle unit 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).
PAGE 230
GRISO 8V - 1200 Chassis Assemble the bearings to the wheel axle. Turn the unit over. Assemble the bearings to the wheel axle.
PAGE 231
GRISO 8V - 1200 Chassis Remove the cover (20). Remove the plug (3) to drain out the oil. Lift the cap (10). Remove the clamps (9) and (11). Remove the cap (14). Remove the screws (16).
PAGE 232
GRISO 8V - 1200 Chassis Collect the ring (15). Remove the screws (7). Remove the casing (4). Remove the clamp (12). Remove the cap (14).
PAGE 233
GRISO 8V - 1200 Chassis Collect the ring (13). Remove the support unit (8). TROUBLESHOOTING Possible Cause 1. Fitting error of the radial seal or seal damaged 2. Sliding surface of the wheel axle seal spoiled or damaged 1. Casing not sealed 2. Closing screws of the casing shells not tightened to the prescribed torque. 1. Dirt between sealing ring and casing 2. Worn sealing ring fitted 3. Plug not tightened to the prescribed torque 1. Damaged cap 2. Retaining clamps or closing cover slacken 3.
PAGE 234
GRISO 8V - 1200 Chassis Installing • Insert the transmission casing on the fork making sure that the universal joint engages correctly. • Tighten the four screws to the prescribed torque operating diagonally. • 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 235
GRISO 8V - 1200 • Place the rear wheel on the fork. • Tighten the four screws with their Chassis spacers and the dust-protection ring. • Place the cover. • Place the rear brake calliper on the disc and the brake pipe on the fork. Exhaust Key: 1. Right exhaust pipe 2. Left exhaust pipe 3. Gasket 4. Nut 5. Washer 6. Washer 7. Washer 8. Washer 9. Gasket 10.
PAGE 236
GRISO 8V - 1200 Chassis 11.Central exhaust pipe 12.Heat-protecting cover 13.Lambda Probe 14.Clamp 15.Gasket 16.Silencer 17.Screw 18.Washer 19.Muffler rubber ring 20.Spacer 21.Silencer fixing bushing 22.Nut 23.Silent-block 24.Screw 25.Screw 26.Washer 27.Nut Removing the tail pipe • Loosen the sealing clamp between the exhaust and the central manifold. • Undo and remove the front screw fastening the exhaust to the chassis.
PAGE 237
GRISO 8V - 1200 • Chassis Undo and remove the rear attachment screw fixing the exhaust to the chassis; collect the locking nut, the spacer and the washer. DURING THIS OPERATION SUPPORT THE EXHAUST SO THAT IT DOES NOT FALL. Locking torques (N*m) Silencer to chassis connecting pipe retainer 25 Nm • Remove the exhaust end. Removing the manifold - tail pipe • Remove the exhaust end and the exhaust manifolds. • Remove the starter motor protection in order to disconnect the lambda probe connector.
PAGE 238
GRISO 8V - 1200 Chassis • Undo and remove the three screws from the protection of the exhaust clamps. • Remove the protection. • Unscrew and remove the two nuts on the head exhaust stud bolts. • Collect the washers. • Loosen the clamp. • Remove the exhaust manifold.
PAGE 239
GRISO 8V - 1200 Chassis Engine oil cooler Key: 1. Complete oil radiator 2. From the oil pump 3. To the heads 4. T-shaped bushing 5. Screw 6. Radiator grille 7. Air deflector 8. Screw 9. Washer 10.Bushing 11.Spacer 12.Rubber ring 13.Cover 14.Spacer 15.Screw 16.Washer 17.Screw 18.
PAGE 240
GRISO 8V - 1200 Chassis Removing • Place a collecting container and empty the lubrication system. • Undo and remove the two screws; collect the pipes and the four washers. • Undo and remove the rear screw; collect the washer. • Undo and remove the two screws; collect the washers. • Undo and remove the screw; collect the washer. • Remove the oil radiator.
PAGE 241
GRISO 8V - 1200 Chassis Installing • Fit the oil radiator on the vehicle following the operations described in the removal chapter but in reverse order. • Unscrew the filler cap / dipstick (1). • Pour new oil until it goes over the minimum level marked "MIN" on the dipstick (1). • Screw the dipstick (1). • Start the vehicle and let the engine run for a few minutes so that the oil circulates and fills the radiator internal ducts. • Stop the engine and check the oil level with the dipstick (1).
PAGE 242
INDEX OF TOPICS BRAKING SYSTEM Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten BRAK SYS
PAGE 243
GRISO 8V - 1200 Braking system Rear brake calliper Key: 1. Rear brake calliper 2. Screw 3. Pads 4. Pin + calliper split pin 5. Spring 6. Gasket 7. Screw 8. Air bleed 9. Air bleed cap 10.Rear brake pipe 11.
PAGE 244
GRISO 8V - 1200 Braking system Front brake calliper Key: 1. Front right brake calliper 2. Front left brake calliper 3. Pads 4. Air bleed 5. Air bleed cap 6. Pins + Calliper springs 7. Spring 8. Aluminium gasket 9.
PAGE 245
GRISO 8V - 1200 Braking system Removal • Turn the pins and remove both split pins. • Remove both pins. • Remove the vibration-damping plate. • Extract one pad at a time. CAUTION AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE CONTROL LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS.
PAGE 246
GRISO 8V - 1200 Braking system Installing • Insert two new pads, placing them so that the holes are aligned with the calliper holes. CAUTION ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED INSIDE THE CALLIPER. • Position the anti-vibration plate. • Insert both pins. • Position both split pins. • Abut the plungers against the pads, acting on the brake pump lever several times. • Check the brake fluid level in the reservoir.
PAGE 247
GRISO 8V - 1200 Braking system Removal • Free the brake pipe and the throttle grip cable from the clamps. • Undo and remove the two screws. • Remove the brake calliper from the disc. • Turn the pin and remove the split pin. • Remove the split pin. • Remove the pin.
PAGE 248
GRISO 8V - 1200 Braking system • 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. Installing • Insert two new pads, placing them so that the holes are aligned with the calliper holes. CAUTION ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED INSIDE THE CALLIPER. • Insert the pin. • Position the split pin.
PAGE 249
GRISO 8V - 1200 Braking system Bleeding the 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 efficiency during braking. The presence of air is signalled by the "sponginess" of the brake control and poor braking efficiency.
PAGE 250
GRISO 8V - 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. NOTE WHILE PURGING THE HYDRAULIC SYSTEM, FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID. CHECK THAT, DURING THE OPERATION, THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR. • Screw the bleed valve and remove the pipe.
PAGE 251
GRISO 8V - 1200 Braking system tainer. This will release the tension on the brake lever and will make it reach the end of stroke. • Close the bleed valve before the lever reaches its end of stroke. • Repeat the operation until the fluid draining into the container is air-bubble free. NOTE WHILE PURGING THE HYDRAULIC SYSTEM, FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID CHECK THAT, DURING THE OPERATION, THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR.
PAGE 252
INDEX OF TOPICS CLUTCH SYSTEM Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten CLU SYS
PAGE 253
GRISO 8V - 1200 Clutch system Both blow-by and clutch pipes should be laid, in the front part of the chassis, underneath the main cable harness. Clutch system pipes laying on the right-hand size of the vehicle.
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INDEX OF TOPICS BODYWORK Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten BODYW
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GRISO 8V - 1200 Bodywork Rider footrest plate RIGHT • Undo and remove the two lower screws and collect the nuts and the spacers. • Free the rear brake pipe from the clamps and from pipe guide. • Remove the rear brake calliper from the disc. • Undo and remove the rear upper screw and collect the nut. • Undo and remove the front upper screw. • Remove the air filter housing. • Disconnect the connector of the rear brake lever switch and release it from the clamps.
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GRISO 8V - 1200 Bodywork • Remove the right footrest plate, keeping the brake fluid reservoir in vertical position. LEFT • Remove the exhaust silencer. • Undo and remove the screw and collect the nut and the spacer. • Undo and remove the rear upper screw and collect the nut. • Undo and remove the front upper screw.
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GRISO 8V - 1200 • Bodywork Undo and remove the screw and remove the left footrest plate. See also Air box Air box • Remove the fuel tank. • Disconnect the connector from the air temperature sensor. • Slide off and remove the main fuse box from its holder. • Undo and remove the four screws.
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GRISO 8V - 1200 Bodywork • Slide off and remove the secondary fuse box from its holder. • Undo and remove the two screws. • Disconnect the low pressure pipe. • Disconnect the blow-by tank breather pipe. • Free the pipes from the clamps.
PAGE 259
GRISO 8V - 1200 • Bodywork Release the breather pipe from the clamp on the right side of the filter casing and the remove the pipe. • Working on both sides, loosen the clamp. • Remove the filter casing by sliding it backwards; collect the blow-by drain pipe. See also Fuel tank Fuel tank • Remove both side fairings and the saddle. • Undo and remove the two front screws fixing the tank. • Undo and remove the two rear screws fixing the tank and collect the two T spacers. • Remove the battery.
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GRISO 8V - 1200 Bodywork • Disconnect the connector. • Remove the fuel tank.
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INDEX OF TOPICS PRE-DELIVERY Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten PRE DE
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GRISO 8V - 1200 Pre-delivery Carry out the listed checks before delivering the vehicle. WARNING BE EXTREMELY CAUTIOUS WHEN HANDLING FUEL.
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GRISO 8V - 1200 Pre-delivery - Through the diagnosis tool, check that the last mapping version is present in the control unit/s and, if required, program the control unit/s again: consult the technical service website to know about available upgrades and details regarding the operation. CAUTION TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE. INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST USED SHORTENS BATTERY LIFE.
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GRISO 8V - 1200 Pre-delivery - Response to throttle control - Stability when accelerating and braking - Front and rear brake efficiency - Front and rear suspension efficiency - Abnormal noise Static test Static check after test drive: - Restarting when warmed up - Starter operation (if present) - Minimum holding (turning the handlebar) - Uniform turning of the steering - Possible leaks - Radiator electric fan operation (if present) Functional inspection - Hydraulic braking system - Stroke of brake and c
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A Air filter: 37 B Battery: 51, 56 Brake: 243, 244, 246 C Clutch: 72, 121, 123, 124, 156, 253 Clutch lever: 72 D Display: 184 E Engine oil: 33, 70, 239 F Fork: 188, 190, 193, 198 Forks: 109 Fuel: 86, 115, 259 Fuses: 53 G Gearbox oil: 35 I Identification: 10 Instrument panel: 75 M Maintenance: 8, 31 O Oil filter: 35 R Recommended products: 22, 218 S Shock absorber: Shock absorbers: 208 Stand: 73 Start-up: 52 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten
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T Tank: 86, 115, 259 Transmission: 12, 32 Tyres: 14 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten