SERVICE STATION MANUAL 897237 Norge GT 8v
SERVICE STATION MANUAL Norge GT 8v While the basic features as described and illustrated in this manual remain unchanged, Moto Guzzi s.p.a. reserves the right to introduce changes to their own models at any time. All rights regarding electronic data storage, total or partial reproduction or adaptation of this manual by any means are reserved for all Countries. Third party products or services referred to in this manual should be considered only informative and are not binding. Moto Guzzi s.p.a.
SERVICE STATION MANUAL Norge GT 8v This manual provides the main information to carry out regular maintenance operations on your scooter. This manual is intended to Moto Guzzi Dealers and their qualified mechanics; several concepts have been deliberately omitted as they are considered unnecessary. As it is not possible to include complete mechanical notions in this manual, users should have basic mechanical knowledge or minimum knowledge about the procedures involved when repairing scooters.
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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 BODYWORK BODYW PRE-DELIVERY PRE DE Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten
INDEX OF TOPICS CHARACTERISTICS CHAR Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten
Norge GT 8v Characteristics Rules Safety rules Carbon monoxide If you need to keep the engine running while working on the vehicle, please ensure that you do so in an open or very well ventilated area. Never let the engine run in an enclosed area. If you do work in an enclosed area, make sure to use a fume extraction system. CAUTION EXHAUST EMISSIONS CONTAIN CARBON MONOXIDE, A POISONOUS GAS WHICH CAN CAUSE LOSS OF CONSCIOUSNESS AND EVEN DEATH.
Characteristics Norge GT 8v BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE 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 THESE SYSTEMS. BRAKE AND CLUTCH FLUIDS ARE EXTREMELY HARMFUL FOR YOUR EYES. IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THEM IMMEDIATELY WITH PLENTY OF COLD, CLEAN WATER AND SEEK MEDICAL ADVICE. KEEP OUT OF THE REACH OF CHILDREN.
Norge GT 8v Characteristics • Keep mated parts together since they have "adjusted" to each other due to normal wear. • Some components must be used together or replaced altogether. • Keep away from heat sources. REASSEMBLING COMPONENTS CAUTION BEARINGS MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE, THEY NEED TO BE REPLACED. • Only use ORIGINAL Moto Guzzi SPARE PARTS. • Comply with lubricant and consumables use guidelines.
Characteristics Norge GT 8v IN ENSURING VEHICLE SAFETY AND MUST COMPLY WITH SPECIFIED VALUES. CHECK THE TIGHTENING TORQUES OF FASTENING ELEMENTS ON A REGULAR BASIS AND ALWAYS USE A TORQUE WRENCH TO REASSEMBLE THESE COMPONENTS. FAILURE TO COMPLY WITH THESE RECOMMENDATIONS MAY CAUSE ONE OF THESE COMPONENTS TO LOOSEN OR EVEN DETACH, CAUSING A WHEEL TO LOCK OR COMPROMISING VEHICLE HANDLING. THIS MAY LEAD TO FALLS, WITH THE RISK OF SERIOUS INJURY OR DEATH.
Norge GT 8v Characteristics ENGINE NUMBER The engine number is stamped on the left side, close to the engine oil level check cap. This number consists of numbers and letters, as in the example shown below.
Norge GT 8v Characteristics Specification Clutch Desc.
Norge GT 8v Characteristics Specification Dashboard lighting Turn indicator warning light Neutral gear warning light Side stand down warning light Low fuel warning light High beam warning light ABS warning light Gear shift warning light Antitheft device warning light Alarm warning light Desc./Quantity LED LED LED LED LED LED LED LED LED LED Frame and suspensions CHASSIS Specification Type Trail Headstock angle Steering angle Front Front wheel travel Rear Rear wheel travel Desc.
Norge GT 8v Characteristics Wheels and tyres WHEELS AND TYRES Specification Wheel rims - type Wheel rims - front Wheel rims - rear Tyre type Front tyre size Front tyre pressure Front tyre pressure with passenger Rear tyre size Rear tyre pressure Rear tyre pressure with passenger Desc./Quantity hollow 3-spoke rim in chilled cast aluminium alloy 3.5 '' x 17'' 5.5 '' x 17'' DUNLOP Roadsmart - Pirelli Angel 120/70 - ZR 17'' 2.5 bar (250 kPa) (36.26 PSI) 2.5 bar (250 kPa) (36.26 PSI) 180 / 55 - ZR 17'' 2.
Norge GT 8v Characteristics FRONT LIGHTS pos. 1 2 Description Headlamp fixing screw Horn fixing screw pos. 1 Description Instrument panel fixing screw Type M5 M6 Quantity 4 1 Torque 6 Nm (4.42 lbf ft) 10 Nm (7.37 lbf ft) Notes - Quantity 3 Torque 3 Nm (2.21 lbf ft) Notes - 1 1 25 Nm (18.
Norge GT 8v Characteristics FRONT FORK pos. 1 2 3 Description Wheel axle locking screw on the fork leg Piston fixing screw to the sleeve Fork cap pos. 1 Description Top fairing fixing screw Type M6 M10x35 - Quantity 4 2 2 Torque 10 Nm (7.37 lbf ft) 50 Nm (36.87 lbf ft) 20 Nm (14.75 lbf ft) Notes - Torque 4 Nm (2.
Norge GT 8v pos. 2 Description Top fairing fixing screw pos. 1 Description Front brake pump U-bolt fixing screw Characteristics Type M5x16 Quantity 2 Torque 4 Nm (2.95 lbf ft) Notes - Torque 10 Nm (7.
Norge GT 8v Characteristics CLUTCH CONTROL pos. 1 2 Description Clutch pipe fixing slot screw Clutch pump U-bolt fixing screw pos. 2 Description Half-handlebar lower fixing screw on the upper steering yoke Half-handlebar upper fixing screw on the upper steering yoke Type M10 M6 Quantity 3 2 Torque 10 Nm (7.37 lbf ft) 10 Nm (7.
Norge GT 8v Characteristics WINDSHIELD pos. 1 2 3 4 5 Description Windshield link rod fixing screw on the frame Aesthetic support fixing screw Engine guide lock to frame upper fixing screw Engine guide lock to frame lower fixing screw Windshield support fixing screw Type M6x25 M5 M6 M6 M6 Quantity 2 4 2 2 4 Torque 10 Nm (7.37 lbf ft) 4 Nm (2.95 lbf ft) 10 Nm (7.37 lbf ft) 10 Nm (7.37 lbf ft) 10 Nm (7.
Norge GT 8v Characteristics FRONT MUDGUARD pos. 1 Description Front mudguard fixing screw pos. 1 2 3 4 5 6 Description Fork stanchion fixing screw on the upper plate Fork stanchion fixing screw on the lower plate Upper yoke fixing cap Headstock ring nut Headstock counter-lock ring Pipe stop plate fixing screw to the steering base Type M5x12 Quantity 4 Torque 4 Nm (2.95 lbf ft) Notes - Torque 25 Nm (18.44 lbf ft) 25 Nm (18.44 lbf ft) 100 Nm (73.76 lbf ft) 40 Nm (29.50 lbf ft) 10 Nm (7.
Norge GT 8v Characteristics FRONT BRAKE CALLIPERS pos. 1 Description Front brake calliper fixing screws pos. 1 2 3 Description Front wheel spindle nut Front brake disc fixing screw Front tone wheel fixing screw Type M10 Quantity 4 Torque 50 Nm (36.87 lbf ft) Notes - Torque 80 Nm (59.00 lbf ft) 25 Nm (18.44 lbf ft) 4 Nm (2.
Norge GT 8v Characteristics pos. 4 Description Front ABS sensor fixing screw Type M6 Quantity 1 Torque 10 Nm (7.37 lbf ft) Notes - Torque 10 Nm (7.37 lbf ft) Notes - FRONT FRAME pos.
Norge GT 8v Characteristics MAIN CABLE HARNESS pos. 1 2 3 4 5 6 7 8 Description Electronic control unit lower fixing screw Electronic control unit upper fixing screw Coil support plate fixing screw Coil fixing screw to the support plate Timing sensor fixing screw Oil temperature sensor support fixing screw Oil temperature sensor Type M6x20 M6x35 M6x20 M4x25 M5x12 M10x20 - Quantity 4 4 4 8 2 1 1 Torque 10 Nm (7.37 lbf ft) 10 Nm (7.37 lbf ft) 10 Nm (7.37 lbf ft) 2 Nm (1.47 lbf ft) 6 Nm (4.
Norge GT 8v Characteristics GEAR CONTROL pos. 1 2 3 4 Description Gearbox lever fixing screws Peg to lever locking screw Rod fixing nut Transmission lever on the gear locking screw Type M6x20 M6x16 M6 M6x20 Quantity 1 1 2 1 Torque 10 Nm (7.37 lbf ft) 10 Nm (7.37 lbf ft) 10 Nm (7.37 lbf ft) 10 Nm (7.
Norge GT 8v Characteristics REAR BRAKE LEVER pos. 1 2 3 4 5 6 7 Description Rear brake pump fixing screw Rear brake pedal fixing screw Spring on the brake pedal return fixing screw Lock nut on the rear brake pump rod Rear brake tank support fixing screw Rear brake tank support clamping screw Peg to lever fixing screw Type M6x20 M8 M5x16 M6 M6 SWP M5x20 M6x16 Quantity 2 1 1 1 1 1 Torque 10 Nm (7.37 lbf ft) 15 Nm (11.06 lbf ft) 6 Nm (4.42 lbf ft) 10 Nm (7.37 lbf ft) 3 Nm (2.
Norge GT 8v Characteristics BRAKE SYSTEM pos. 1 2 3 Description Brake pipe slot screw on the pump Joint with brake pipes retainer bleeding on the calliper Brake pipes joint on the ABS hydraulic unit Type M10 M10 Quantity 2 3 Torque 25 Nm (18.44 lbf ft) 25 Nm (18.44 lbf ft) Notes - - 4 25 Nm (18.
Norge GT 8v Characteristics FOOTRESTS pos. 1 2 Description Rubber footrest fixing screw Rider footrest friction pin Type M6 M8 pos. 1 Description Footrest plate to chassis front upper fixing screw Footrest plate to chassis rear upper fixing screw Right footrest plate to chassis lower fixing screw Left footrest plate to chassis lower fixing screw Quantity 8 2 Torque 10 Nm (7.37 lbf ft) 25 Nm (18.
Norge GT 8v Characteristics FUEL TANK pos. 1 2 3 4 Description Tank to chassis front fixing screw Tank to chassis rear fixing screw Tank breather joint Filler to tank fixing screw Type M8 M8 M6 M5 Quantity 2 1 2 4 Torque 25 Nm (18.44 lbf ft) 25 Nm (18.44 lbf ft) 6 Nm (4.42 lbf ft) 4 Nm (2.
Norge GT 8v Characteristics FRAME pos. 1 2 3 4 Description Plate to chassis fixing screw Plate to engine fixing nut Gear to chassis upper fixing pin Gear to chassis lower fixing pin Type M12x50 M10 M12 M12x270 Quantity 2 4 1 1 Torque 50 Nm (36.87 lbf ft) 80 Nm (59 lbf ft) 80 Nm (59 lbf ft) 80 Nm (59 lbf ft) Notes - Type M8x25 M5x9 Quantity 5 10 Torque 25 Nm (18.44ft) 4 Nm (2.95 lbf ft) Notes - M8 4 20 Nm (14.75 lbf ft) - Back side TAIL Tail pos.
Norge GT 8v Characteristics TRANSMISSION CONNECTION - ENGINE pos. 1 Description Reaction rod fixing screw pos. 1 Description Swingarm clamp fixing screw on the bushing Type M10x55 Quantity 2 Torque 50 Nm (36.87 lbf ft) Notes - Torque 10 Nm (7.
Norge GT 8v pos. 2 3 4 Description 2 - Swingarm fixing screw on the transmission housing Swingarm pin on the swingarm Preloading bushing to the swingarm pin Characteristics Type M10x35 Quantity 4 Torque 50 Nm (36.87 lbf ft) Notes - M12 M25 1 1 60 Nm (44.25 lbf ft) 10 Nm (7.37 lbf ft) - Quantity 4 2 Torque 4 Nm (2.95 lbf ft) 2 Nm (1.47 lbf ft) Notes - REAR LIGHTS pos.
Norge GT 8v Characteristics SPLASH GUARD pos. 1 2 Description Splash guard fixing screw to the chassis ABS support fixing screw to the splash guard 3 Retroreflector support fixing screw to the license plate Retroreflector fixing nut retainer to the support 4 Type M6 SWP M5x20 M5x10 Quantity 6 3 Torque 10 Nm (7.37 lbf ft) 3 Nm (2.21 lbf ft) Notes Loctite 243 - 2 4 Nm (2.95 lbf ft) - M5 1 4 Nm (2.95 lbf ft) - Torque 50 Nm (36.87 lbf ft) Notes - REAR BRAKE CALLIPER pos.
Norge GT 8v Characteristics REAR WHEEL pos. 1 2 3 4 Description Rear wheel fixing screw Rear brake disc fixing screw Rear tone wheel fixing screw Rear ABS sensor fixing screw Type M12x65 M8 M5x12 M6 Quantity 4 6 6 1 Torque 110 Nm (81.13 lbf ft) 25 Nm (18.44 lbf ft) 4 Nm (2.95 lbf ft) 10 Nm (7.
Norge GT 8v Characteristics REAR SUSPENSION pos. 1 2 3 4 5 Description Shock absorber to chassis fixing screw Shock absorber to double connecting rod fixing screw Shock absorber to single connecting rod fixing screw Double connecting rod to swingarm fixing screw Screw fastening single linkage to chassis Type M10x80 M10x82 Quantity 1 1 Torque 50 Nm (36.87 lbf ft) 40 Nm (29.50 lbf ft) Notes - M10x95 1 50 Nm (36.87 lbf ft) - M10x47 1 50 Nm (36.87 lbf ft) - M10x85 1 50 Nm (36.
Norge GT 8v Characteristics ALTERNATOR pos. 1 2 3 Description Generator control pulley locking nut Generator upper fixing screw Generator lower fixing screw Type M16 M8 M10x60 Quantity 1 1 1 Torque 80 Nm (59.00 lbf ft) 22 Nm (16.23 lbf ft) 30 Nm (22.
Norge GT 8v Characteristics CRANKCASE AND OIL SUMP pos.
Norge GT 8v Characteristics OIL SUMP COMPONENTS pos. 1 2 3 4 5 6 Description Cover on the flange under the crankcase Oil filter joint Oil sump pipe Oil filter Rose pipe fixing screw Maximum pressure valve cover Type M6 M18 Quantity 1 1 1 1 1 Torque 40 Nm (29.50 lbf ft) 10 Nm (7.37 lbf ft) 20 Nm (14.75 lbf ft) 15 Nm (11.06 lbf ft) 10 Nm (7.37 lbf ft) 40 Nm (29.
Norge GT 8v Characteristics CYLINDER HEAD COVERS pos. 1 2 Description Special cylinder head fixing screw Type - Quantity 8 Torque 8 Nm (5.90 lbf ft) Spark plug cover fixing screw M5x10 2 8 Nm (5.90 lbf ft) Notes Locked with cross sequence - Torque 10 Nm (7.37 lbf ft) 25 Nm (18.44 lbf ft) 12 Nm (8.85 lbf ft) 12 Nm (8.85 lbf ft) Notes Loctite 243 - GENERATOR COVER pos.
Norge GT 8v Characteristics AIR FILTER pos. 1 2 3 Description Air filter box bracket and cover fixing screw Air temperature sensor fixing screw Air filter box front fixing screw Type Quantity SWP 5x20 7 SWP 2 2.9x12 M6x20 2 Torque 3 Nm (2.21 lbf ft) 2 Nm (1.47 lbf ft) Notes - 4 Nm (2.
Norge GT 8v Characteristics THROTTLE BODY pos. 1 2 Description Intake pipe fixing screw Flange fixing screw on the throttle body Type M5x12 Quantity 6 2 Torque 10 Nm (7.37 lbf ft) 6 Nm (4.42 lbf ft) Notes - pos. 1 Description Clutch to crankshaft fixing screw Type - Quantity 6 Torque 42 Nm (30.98 lbf ft) M7x16 - 6 6 3 20 Nm (14.75 lbf ft) 10 Nm (7.37 lbf ft) 10 Nm (7.
Norge GT 8v Characteristics CONNECTING ROD ASSEMBLY - CYLINDERS pos. 1 2 2 3 4 Description Thermal group fixing stud bolt Connecting rod screws Connecting rod screws Right hydraulic tensioner cover Left hydraulic tensioner cover Type M10x1.25 - Quantity 8 4 4 1 1 Torque 5 Nm (3.69 lbf ft) 40 Nm (29.50 lbf ft) 80 Nm (59.00 lbf ft) 42 Nm (30.98 lbf ft) 30 Nm (22.
Norge GT 8v Characteristics FUEL SUPPLY SYSTEM pos. 1 2 Description Fuel pump support fixing screw to the tank Fuel pump support fixing screw to the tank pos. 1 Description Blow-By tank fixing screw Type M5x20 M5x16 Quantity 2 4 Torque 5 Nm (3.68 lbf ft) 6 Nm (4.42 lbf ft) Notes - Quantity 2 Torque 3 Nm (2.21 lbf ft) Notes - 1 1 20 Nm (14.75 lbf ft) 20 Nm (14.
Norge GT 8v Characteristics STARTER MOTOR pos. 1 2 3 Description Starter motor fixing screw Stud bolt Starter motor cover fixing screw Type M6x10 Quantity 2 1 2 Torque 25 Nm (18.44 lbf ft) 10 Nm (7.37 lbf ft) 8 Nm (5.
Norge GT 8v Characteristics OIL PUMP pos. 1 2 3 Description Oil pump fixing screw Oil pump driven gear locking nut Oil pressure valve cap pos. 1 2 3 Description Solenoid valve to radiator fixing screw Radiator fixing pin on the grille Radiator to grille fixing screw Type M6x45 M6 - Quantity 3 1 1 Torque 10 Nm (7.37 lbf ft) 8 Nm (5.90 lbf ft) 40 Nm (29.50 lbf ft) Notes Loctite 243 Loctite 243 - Torque 4 Nm (2.95 lbf ft) 4 Nm (2.95 lbf ft) 4 Nm (2.
Norge GT 8v Characteristics RIGHT CYLINDER HEAD pos. 1 2 2 3 4 5 6 Description Movable chain tensioner pad fixing screw Head tightening nut Type M10x1.25 Head tightening nut M10x1.25 Head tightening screws (chain compartment) M6x120 Plate locking screw and timing gear Timing cover fixing screw on the cylinder head M5x10 Camshaft support fixing screw - Quantity 1 4 Torque 20 Nm (14.75 lbf ft) 15 Nm (11.06 lbf ft) 4 2 1 2 6 42 Nm (30.98 lbf ft) 10 Nm (7.37 lbf ft) 30 Nm (22.13 lbf ft) 8 Nm (5.
Norge GT 8v Characteristics LEFT CYLINDER HEAD pos. 1 2 2 3 4 5 6 Description Movable chain tensioner pad fixing screw Head tightening nut Type M10x1.25 Head tightening nut M10x1.25 Head tightening screws (chain compartment) M6x120 Plate locking screw and timing gear Timing cover fixing screw on the cylinder head M5x10 Camshaft support fixing screw - Quantity 1 4 Torque 20 Nm (14.75 lbf ft) 15 Nm (11.06 lbf ft) 4 2 1 2 6 42 Nm (30.98 lbf ft) 10 Nm (7.37 lbf ft) 30 Nm (22.13 lbf ft) 8 Nm (5.
Norge GT 8v Characteristics GEARBOX pos. 1 2 3 4 5 Description Clutch housing to gearbox fixing screw Neutral sensor Breather stud bolt Gear oil magnetic drainage cap Oil filler cap Type M6x55 M18x1.5 Quantity 14 1 1 1 1 Torque 13 Nm (9.59 lbf ft) 10 Nm (7.37 lbf ft) 8 Nm (5.90 lbf ft) 24 Nm (17.70 lbf ft) 28 Nm (20.65 lbf ft) Notes Loctite 243 - Overhaul data Assembly clearances Cylinder - piston assy. Measurement of the cylinder diameter must be done at three heights, turning the dial gauge 90°.
Norge GT 8v Characteristics PIN - PISTON COUPLING Specification Pin diameter Pin hole diameter on piston Clearance between pin and holes on piston Desc./Quantity 21.998 - 21.994 mm (0.86606 - 0.86590 in) 22.016 - 22.011 mm (0.86677 - 0.86657 in) 0.013 - 0.022 mm (0.00051 - 0.00087 in) 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.
Norge GT 8v Characteristics Crankcase - crankshaft - connecting rod CRANKSHAFT SEAT (TIMING SYSTEM SIDE) Specification Diameter of crankshaft main journal, timing system side Inside diameter of crankshaft bushing, timing system side Clearance between bushing and main journal (timing system side) Desc./Quantity 37.975 - 37.959 mm (1.49507 - 1.49444 in) 38.016 - 38.0 mm (1.49669 - 1.49606 in) 0.025 - 0.057 mm (0.00098 - 0.
Norge GT 8v Characteristics • Reset the micrometer on the cylinder rim. • Move the tool so that the micrometer feeler reaches the top point of the piston crown. • Take note of the measurement and, according to the values found, consult the chart at the bottom of the page to decide the thickness of the gasket to be fitted between cylinder and head. • Unlock crankshaft rotation. • Rotate the crankshaft by 90°until the right cylinder piston reaches the TDC. • Lock crankshaft rotation.
INDEX OF TOPICS SPECIAL TOOLS S-TOOLS Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten
Norge GT 8v Special tools MOTORE Stores code 020677Y Description Generator belt tensioner, lever for belt tensioning 05.91.17.30 Front cover insertion cone 020716Y Connecting rod locking 020470Y Pin snap ring fitting tool 05.92.72.30 Timing system cover sealing ring punch 01.92.91.
Norge GT 8v Special tools Stores code 05.90.25.30 Description Gearbox support 19.92.96.00 Graduated dial to control ignition timing 12.91.18.01 Tool to lock the flywheel and the starting ring gear 12.91.36.00 Tool to remove the flywheel-side flange AP8140179 Support for valve fitting/removal AP9100838 Tool for valve pressure plate 14.92.71.
Norge GT 8v Special tools Stores code 12.91.20.00 Description Tool to fit the flywheel-side flange together with seal ring on the crankshaft 19.92.71.
Norge GT 8v Special tools Stores code 020678Y Description Tool for clutch rod checking 05.91.25.30 Gearbox opening 14.91.26.03 Hook spanner for fixing ring nut of the clutch shaft internal body CICLISTICA Stores code 020884Y Description 46 mm wrench for steering ring nut BEVEL GEAR SET Stores code 05.90.27.
Norge GT 8v Special tools Stores code 05.90.27.31 Description Gearbox oil seal buffer 05.90.27.32 Buffer handgrip 05.90.27.33 Ball joint sealing buffer 05.90.27.34 Wrench for pinion ring nut 05.90.27.35 Pinion oil seal buffer FORCELLA ANTERIORE Stores code 9100903 Description Marzocchi fork oil seal; ø 45 mm (1.
Norge GT 8v Special tools Stores code AP8140146 Description Weight AP8140149 Protection for fitting operations S-TOOLS - 57 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten
INDEX OF TOPICS MAINTENANCE MAIN Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten
Norge GT 8v Maintenance Maintenance chart Correct maintenance is fundamental for ensuring the longevity of your vehicle and maintaining optimum function and performance. For this purpose, Moto Guzzi has formulated a series of checks and scheduled services (at the owner's expense), are summarised in the table given in the following page. We recommend having any minor faults resolved immediately by an Authorised Moto Guzzi Dealer, without waiting until the next scheduled service interval.
Maintenance Norge GT 8v I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE (1) Check and clean and adjust or replace, if necessary, before every journey. (2) Replace every 2 years or 20000 Km (12427 mi). (3) Replace every 4 years. (4) Check at each engine start. (5) Every 5000 Km if the vehicle is used for racing. Transmission fluid Check • Keep the vehicle upright with both wheels on the ground. • Unscrew and remove the cap/dipstick (1).
Norge GT 8v Maintenance DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCE TO THE FLUID. WHEN USING A FUNNEL OR ANY OTHER ELEMENT, MAKE SURE IT IS PERFECTLY CLEAN. • Screw and tighten the caps (1 - 2). Engine oil Check Check the engine oil level frequently. To check: ENGINE OIL LEVEL MUST BE CHECKED WHEN THE ENGINE IS WARM. CAUTION DO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT STANDSTILL TO WARM UP THE ENGINE AND OBTAIN THE OPERATING TEMPERATURE OF ENGINE OIL.
Maintenance • Norge GT 8v Pull the filler plug / oil level dipstick (1) straight out. • Wipe the oil level dipstick (1) clean and reinsert it. • Pull it out again and check the oil level. • The oil level is correct when it is close to the "MAX" mark. Otherwise, top-up with engine oil. Replacement NOTE HOT OIL IS LESS VISCOUS AND WILL DRAIN OUT MORE EASILY AND COMPLETELY. • Remove the fairing lug • Place a container with 4000 cm³ (244 cu.in) capacity under the drainage plug (2).
Norge GT 8v Maintenance DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT. DISPOSE OF ENGINE OIL IN A SEALED CONTAINER AND TAKE IT TO YOUR SUPPLIER OR TO THE NEAREST USED OIL COLLECTION CENTRE. Engine oil filter Replace the engine oil filter each time you change the engine oil. • Drain the engine oil completely. • Unscrew and remove the engine oil filter from its seat. NOTE NEVER REUSE AN OLD FILTER. • Spread a thin layer of oil on the sealing ring of the new engine oil filter.
Maintenance • Norge GT 8v 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. Replacement NOTE HOT OIL IS MORE FLUID AND WILL DRAIN OUT MORE EASILY AND COMPLETELY. • Place a container with suitable capacity under the drainage plug (2). • Unscrew and remove the drainage plug (2). • Unscrew and remove the filler cap (1).
Norge GT 8v • Remove the oil breather pipe. • Unscrew and remove the five screws. • Lift the filter casing cover. • Remove the acoustic insulation panel. • Remove the air filter. • Cover the inlet duct with a clean cloth Maintenance so that no foreign bodies could get into. NOTE 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 • Remove the fuel tank.
Maintenance • Norge GT 8v Remove the Moto Guzzi logo using a screwdriver. • Remove the spark plug protection. If the timing system is very noisy, check the clearance between the valves and the rocking levers. NOTE ADJUST WITH COLD ENGINE, WITH PISTON AT TOP DEAD CENTRE (TDC) IN COMPRESSION STROKE (VALVES CLOSED). • Disconnect both spark plug boots. • Unscrew and remove the four head cover fixing screws and collect the sealing O-rings. • Remove the head cover together with the gasket.
Norge GT 8v • Maintenance The measurement must be taken using a special thickness gauge. CAUTION IF CLEARANCE IS LARGER THAN RECOMMENDED, THE TAPPETS WILL BE NOISY. OTHERWISE, THE VALVES DO NOT CLOSE CORRECTLY, WHICH CAN LEAD TO PROBLEMS SUCH AS: • PRESSURE DROP; • ENGINE OVERHEAT; • VALVE BURN OUT, ETC. Braking system Level check Brake fluid check • Rest the vehicle on its stand. • For the front brake, hold the handlebar straight.
Maintenance • Norge GT 8v 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. DO NOT OPERATE THE BRAKE LEVER WITH BRAKE FLUID RESERVOIR CAP LOOSENED OR REMOVED. CAUTION AVOID PROLONGED AIR EXPOSURE OF THE BRAKE FLUID. BRAKE FLUID IS HYGROSCOPIC AND ABSORBS MOISTURE WHEN IN CONTACT WITH AIR. LEAVE THE BRAKE FLUID RESERVOIR OPEN ONLY FOR THE TIME NEEDED TO COMPLETE THE TOPPING UP PROCEDURE.
INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten
Norge GT 8v Electrical system MAIN CABLE HARNESS pos. 1 2 3 4 5 6 7 Description Electronic control unit lower fixing screw Electronic control unit upper fixing screw Coil support plate fixing screw Coil fixing screw to the support plate Timing sensor fixing screw Oil temperature sensor support fixing screw Oil temperature sensor Type M6x20 M6x35 M6x20 M4x25 M5x12 M10x20 - Quantity 4 4 4 8 2 1 1 Torque 10 Nm (7.37 lbf ft) 10 Nm (7.37 lbf ft) 10 Nm (7.37 lbf ft) 2 Nm (1.47 lbf ft) 6 Nm (4.
Norge GT 8v Electrical system Components arrangement Key: 1 Coil 2 Instrument panel 3 Fuel pump 4 Injector 5 Throttle valve potentiometer ELE SYS - 71 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten
Electrical system Norge GT 8v 6 Fall sensor 7 Rear light 8 Battery 9 Main fuses 10 Lambda sensor 11 Intake air temperature sensor 12 Engine revolution sensor 13 Auxiliary fuses 14 Head temperature sensor 15 Engine control unit 16 Instrument panel air temperature sensor 17 Front headlamp 18 Key lock with integrated immobilizer aerial 19 Speed sensor 20 Alternator 21 Oil pressure sensor 22 Starter motor 23 ABS Control unit 24 Rear speed sensor 25 Engine oil radiator fan 26 Windshield height adjustment motor
Norge GT 8v • No.1 ECU • No.2 Coils • No.2 Supports for coil • No.2 Coil tongues • No.2 Spark plug hoods together with H.V. cable • No.2 NGK PMR8B Spark Plugs • No.1 Oil pressure sensor • No.1 Oil Temperature sensor • No.1 Throttle Body • No.2 Injectors • No.1 Neutral switch • No.1 Alternator • No.1 Starter Motor • No.2 Relay switch • No.2 30 A Relay with diode • No.2 30 A Relay • No.4 Relay support rubber ring • No.2 Relay support rubber ring • No.1 Horn • No.
Electrical system • No.1 Front left turn indicator • No.1 Rear right turn indicator • No.1 Rear left turn indicator • No.1 License plate lamp • No.1 Taillight • No.1 Front headlight • No.1 Flexible headlamp panel • No.1 Instrument panel • No.1 Airbox air T. sensor • No.1 Stand switch • No.2 Lambda sensors • No.1 Right heated hand grip • No.1 Left heated hand grip • No.1 Windshield motor • No.1 ABS Control unit • No.1 ABS Control unit support • No.1 Front ABS sensor • No.
Norge GT 8v • No. 1 Ix 6.4x12x0.5 Ond Flexible Washer • No. 1 EBFM IX M8X1.25 nut • No. 1 Anti-vibration washer • No. 2 Adhesive cable grommet • No. 6 Cable grommets • No. 1 M6x16 screw • No. 2 TE FL M6x16 screws • No. 1 Cables retainer plate • No. 1 TCEI M6x18 screw • No. 2 SWP T. cross FL M5x20 screws • No. 1 Self-tapping screw for plastic 2.9x12 Electrical system Motorcycle division The wiring distribution is subdivided in three essential sections, as indicated in the figure. 1.
Electrical system • Fuel pump connector • Key Connector • Right Light Switch Connectors • Left Light Switch Connectors • ABS Control Unit Connector and correct positioning of the cap • Front and rear speed sensor connector • Neutral Switch Connector • Engine ground eyelet Norge GT 8v The connectors listed are considered critical in comparison with the others because the vehicle will stop if they are accidentally disconnected.
Norge GT 8v • Electrical system Clamp where indicated. FRONT SECTION - TABLE B: RIGHT LIGHT SWITCH 1. Cable retainer plate, to stop the cable from: right device, down windshield button, stop switch, right heated hand grip e throttle grip. 2. Clamps. FRONT SECTION - TABLE B1: RIGHT LIGHT SWITCH 1. Connect the faston of the brake switch, taking care not to bend it. 2. Right heated hand grip cable.
Electrical system Norge GT 8v FRONT SECTION - TABLE B2: RIGHT LIGHT SWITCH 1. Windshield right down button connection cable, recognisable by the white belt. FRONT SECTION - TABLE C: LEFT LIGHT SWITCH 1. Clamps FRONT SECTION - TABLE C1: LEFT LIGHT SWITCH 1. Clutch switch (wired). 2. UP button connector (to be connect to N.A. button). FRONT SECTION - TABLE C2: LEFT LIGHT SWITCH 1. The cable coming from the right half-handlebar pass through the forks present on the chassis.
Norge GT 8v Electrical system FRONT SECTION - TABLE D: FRONT MAIN CABLE HARNESS 1. Lights relay cable harness. 2. Low-beam/high-beam light relay cable harness. 3. Instrument panel fixing clip. The connectors of the left device and of the immobilizer must be above the fixing clip of the instrument panel. FRONT SECTION - TABLE D1: FRONT MAIN CABLE HARNESS 1. Clamp. 2. Lights relay connector. 3. Immobilizer connector. 4. Left light switch connectors. 5. Windshield driving engine connector. 6. Clip.
Electrical system Norge GT 8v FRONT SECTION - TABLE D3: FRONT MAIN CABLE HARNESS 1. Instrument panel connector. FRONT SECTION - TABLE D4: FRONT MAIN CABLE HARNESS 1. Immobilizer connector. FRONT SECTION - TABLE D5: FRONT MAIN CABLE HARNESS 1. Right headlamp connector. 2. Left headlamp connector. The connectors of the left and right front headlamp can be connected interchangeably without causing malfunctions and must be located behind the main cable harness branch.
Norge GT 8v Electrical system FRONT SECTION - TABLE E: FRONT ABS SENSOR 1. Cable grommets. FRONT SECTION - TABLE E1: FRONT ABS SENSOR 1. Brake pipe fixing plate. 2. Chassis fork. 3. Front ABS sensor cable. FRONT SECTION - TABLE F: TURN INDICATORS 1. Cable guide. 2. Right turn indicator connector. 3. Left turn indicator connector.
Electrical system Norge GT 8v Central part CAUTION ONCE THE ELECTRICAL SYSTEM IS REFITTED, THE CONNECTORS RECONNECTED AND CLAMPS AND RETAINERS RESTORED, CARRY OUT THE CHECKS INDICATED UNDER "SPECIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES" IN THE "ELECTRICAL SYSTEM INSTALLATION" SECTION. CENTRAL SECTION TABLE A: ELECTRIC FAN CABLE HARNESS PREPARATION 1. Electric fan connector. 2. Clamps. 3. Clip. TABLE A1: ELECTRIC FAN CABLE HARNESS PREPARATION 1. Electric fan connector.
Norge GT 8v Electrical system TABLE A3: ELECTRIC FAN CABLE HARNESS PREPARATION 1. Clamp. 2. Bracket. TABLE B: MAIN CABLE HARNESS ON THE CHASSIS 1. Clamps. 2. Align the grey belt on the main cable harness with the pipe. TABLE B1: MAIN CABLE HARNESS ON THE CHASSIS 1. Horn. 2. Clamp. 3. Faston Horn (x2) TABLE B2: MAIN CABLE HARNESS ON THE CHASSIS 1. Clamp. 2. The main cable harness, in the central area of the motorbike, passes inside the chassis.
Electrical system Norge GT 8v TABLE B3: MAIN CABLE HARNESS ON THE CHASSIS 1. ECU control unit. Connect the ECU connectors like in the figure, being careful to attach the slides to the bottom. 2. ECU ground. TABLE B4: MAIN CABLE HARNESS ON THE CHASSIS 1. Clamp. 2. GPS pre-installation. TABLE B5: MAIN CABLE HARNESS ON THE CHASSIS 1. Arrange the connectors of the right light switch device to the connection. 2. The instrument panel branch must be passed through the upper triangle of the chassis. 3.
Norge GT 8v Electrical system TABLE C1: COILS 1. Laying of the H.V. cable Connect the spark plug hood to the other end of the H.V. cable and repeat the laying on the left side. TABLE D: MAIN CABLE HARNESS 1. Injection branch. 2. Injection sub-branch. 3. Grey sheathing. From the injection branch select the sub-branch with three connectors of which one blue (engine cylinder head temperature) and direct it towards the right side of the motorbike.
Electrical system Norge GT 8v TABLE F: THROTTLE SENSOR 1. Connect the throttle sensor making sure that the hook of the connector anchors onto the rear lock present on the component. TABLE G 1. Pick up. 2. Front ABS sensor connector. TABLE H: OIL PRESSURE SENSOR 1. Oil pressure sensor. 2. Grey sheathing of the oil pressure sensor cable harness reference. TABLE I: INJECTORS 1. Right injector connector. 2. Left injector connector.
Norge GT 8v Electrical system TABLE J: STEPPER MOTOR 1. Engine stepper connector. TABLE K 1. Key connector. 2. Clutch switch connector. 3. Heated hand grips connector. 4. Electric fan cable harness connector. 5. Clamp. TABLE L 1. Alternator eyelet. 2. Generator connector 3. Alternator. 4. Right device connectors. 5. Alternator eyelet hood.
Electrical system Norge GT 8v TABLE M 1. Fall sensor. 2. Injection relay 2. 3. Injection relay 1. 4. Start-up relay. 5. Maintenance relay. TABLE N 1. Fuel pump connector. 2. Rear ABS sensor connector. 3. Rear stop switch connector.
Norge GT 8v Electrical system TABLE O 1. Fixing stud bolt and anti-vibration washers. 2. Negative battery cable harness - ground. 3. Side stand switch connector. 4. Engine ground eyelet (main cable harness). TABLE P 1. Starter motor. 2. Clamp. 3. Battery ground cable harness path - engine ground. TABLE Q 1. Starter motor connector. 2. Starter motor eyelet. 3. Clamp. 4. ABS ECU connector. The hood of the ABS ECU connector must be bent toward the front of motorcycle. TABLE R 1.
Electrical system Norge GT 8v TABLE S 1. Air temperature connector (filter box). TABLE T: LAMBDA SENSOR 1. Right lambda connector. 2. Left lambda connector. 3. Clamps. 4. Clamp with which the electric fan cable harness must be held. 5. Right lambda sensor. 6. Left lambda sensor. Each lambda cable must be connected with two clamps.
Norge GT 8v Electrical system TABLE U: PROCEDURE FOR THE CORRECT INSERTION OF THE ABS CONTROL UNIT CONNECTOR • Place the connector on the opposite side of the control unit and lower the driving lever until the "click" that signals the end of the stroke is heard. TABLE U1: CORRECT ASSEMBLY • When the connector is fully inserted, the distance between the connector and the ABS control unit must be 7.5 mm (0.29 in).
Electrical system Norge GT 8v TABLE B 1. Clamp. TABLE C 1. Clamp. 2. License plate lamp, taillight AND rear turn indicator connectors. TABLE D 1. Battery. 2. Positive pole (red heat-shrinking). 3. Negative pole. TABLE E 1. Secondary fuse box, ECU diagnosis connectors and instrument panel diagnosis.
Norge GT 8v Electrical system TABLE F 1. Main fuses 1. 2. Main fuses 2. TABLE G: REAR ABS SENSOR 1. Cable grommets TABLE G1: REAR ABS SENSOR 1. Rear brake switch cable harness. 2. Clamp. 3. Rear ABS sensor cable harness.
Electrical system Norge GT 8v General wiring diagram 1. Multiple connectors 2. Clutch switch 3. Start-up relay 4. Start-up maintenance relay 5.
Norge GT 8v Electrical system 6. Light logic relay 7. Right light switch 8. Power supply for GPS 9. Horn 10.Left light switch 11.Ambient air temperature sensor 12.Instrument panel 13.Immobilizer aerial 14.Ignition switch 15.Heated handgrips 16.Rear right turn indicator 17.Taillight (LED) 18.Left rear turn indicator 19.License plate light bulb 20.Rear stop switch 21.Front stop switch 22.ABS Control unit 23.Front wheel speed sensor 24.Rear wheel speed sensor 25.Secondary fuses 26.Starter motor 27.
Electrical system Norge GT 8v 44.Idle motor 45.Throttle position sensor 46.Right cylinder coil 47.Left cylinder coil 48.Right spark plug 49.Left spark plug 50.Right cylinder injector 51.Left cylinder injector 52.Fall sensor 53.Pick-up 54.ECU. 55.Front left turn indicator 56.Complete front headlamp 57.Tail light bulb 58.Low beam bulb 59.High beam bulb 60.Front right turn indicator 61.62.Instrument panel diagnosis 63.ECU Diagnosis.
Norge GT 8v Electrical system Dashboard Diagnosis Changing the CODE If you know the code, just enter it and then a new code that will be automatically stored in the memory. If the vehicle is new, the user code is: 00000 Resetting the CODE This function is used to set a new code when the old one is not available; in this case, at least two of the programmed keys have to be inserted in the ignition lock.
Electrical system Norge GT 8v Low Battery Error ECU 20 Lambda Probe Error ECU 21 Coil 1 Error DC V DC ECU 22 Coil 1 Error DC Gnd ECU 23 Coil 2 Error DC V DC ECU 24 Coil 2 Error DC Gnd ECU 25 Injector 1 Error DC V DC ECU 26 Injector 1 Error DC Gnd ECU 27 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 Err
Norge GT 8v Electrical system This option deletes instrument panel errors only, a further confirmation is requested. INSTRUMENT PANEL SOFTWARE UPGRADE This function is used to program the instrument panel again with a new software through Navigator. The Display reads: "Instrument panel disconnected. Now connect the diagnosis instrument"; the instrument panel will connect normally after the key is extracted-inserted.
Electrical system Norge GT 8v Checking the stator Single-phase generator with regulated voltage Maximum load 40A (550W) Charging voltage 14.2 - 14.8 V (5000 rpm) Start-up system check pick-up input about 100 A level indicators Petrol pump: Input: 3.5 A (to be measured between pins 1 and 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.
Norge GT 8v Electrical system Lights list FRONT HEADLAMP Tail light: 12V - 5W Low beam light: 12V - 55W H3 High beam light: 12V - 65W H1 REAR LIGHT LED Fuses SECONDARY FUSES DISTRIBUTION 1 Specification (a) 15A fuse 2 (b) 15A fuse 3 4 5 (c) 15A fuse (d) 10A fuse (e) 3A fuse 6 (f) 10A fuse 7 3A - 10A - 15A Desc./Quantity Stop, horn, GPS, HAZARD button backlight, light relay coils, high beam flash, electric windshield motor (if fitted).
Norge GT 8v Electrical system MAIN FUSES - DISTRIBUTION Specification (G) 40A fuse (H) 30A fuse (I) 20A fuse (J) 20A fuse 20A (QUANTITY' 2) - 30A - 40A 1 2 3 4 5 Desc.
Norge GT 8v Electrical system Speed sensor FRONT FUNCTION:To indicate the vehicle speed by reading the front wheel turning speed. OPERATION / OPERATING PRINCIPLE:Magnetoresistive sensor: a square-wave pulse is generated with voltage approx. between 11.55 V and 11.25 V WIRING DIAGRAM Level in wiring diagram: ABS. REMOVAL LOCATION ON THE VEHICLE:on the fork, right stem, next to the brake calliper support. CONNECTOR LOCATION (if available): under the fuel tank, front position.
Electrical system Norge GT 8v Troubleshooting: Check speed sensor retainer. If it is not OK, restore it. If it is OK, check if the tone wheel is dirty, deformed or wrongly fixed. If any of this happens, replace the tone wheel. Otherwise, replace the speed sensor. 5D92 the signal decreases periodically: Possible tone wheel fault due to deformations or dirt; possible alterations on the wheel bearing surface. In very rare cases, abnormal tone wheel vibrations.
Norge GT 8v Electrical system LOCATION ON THE VEHICLE:Under the bevel gear set box, right side. CONNECTOR LOCATION (if available):Under the saddle, right side. PIN-OUT: • PIN1 - Ground • PIN2 - Signal NAVIGATOR Parameters: Speed (km/h) - Vehicle speed. ELECTRICAL ERRORS Speed sensor 5DA0 electric malfunction:Electrical fault in sensor or cable harness.
Electrical system Norge GT 8v wheel has the correct number of teeth or if it is dirty, deformed or wrongly fixed. If it is not OK, replace the tone wheel and if it is OK, replace the speed sensor. 5DA4 missing acceleration after pressure reduction: Faulty sensor or missing sensor/tone wheel or excessive distance between the sensor and the tone wheel. Troubleshooting: Check that the speed sensor and the tone wheel are installed. If they are not, install them. If they are, check the speed sensor retainer.
Norge GT 8v Electrical system 1. Engine revolution sensor positive signal. 2. Engine revolution sensor negative signal. 3. Revolution sensor anti-jamming cable. NAVIGATOR: PARAMETERS Target engine revs Example value:1100 +/- 100 rpm Parameter valid at idle, setting depends especially on engine temperature: the ECU unit will try to keep the engine running at this revs, acting on the ignition advance.
Electrical system Norge GT 8v Location: • sensor: on the right cylinder throttle body • connector: on the potentiometer Electrical characteristics: • PINS A-C: throttle closed approx. 2.5 kOhm; throttle open approx. 1.5 kOhm. • PINS A-B: approx. 1.
Norge GT 8v Electrical system connector A (BROWN) and PIN C of the sensor (red cable): if there is not continuity, restore the cable harness; if there is continuity, check continuity of the sensor between PIN A and PIN C: if there is not continuity, replace the potentiometer; if there is continuity, check the resistance. If resistance is over 2.
Norge GT 8v Electrical system Specification Resistance at +10 °C (50 °F) Resistance at +20 °C (68 °F) Resistance at +30 °C (86 °F) Resistance at +40 °C (104 °F) Resistance at +50 °C (122 °F) Resistance at +60 °C (140 °F) Resistance at +70 °C (158 °F) Resistance at +80 °C (176 °F) Resistance at +90 °C (194 °F) Resistance at +100 °C (212 °F) Resistance at +110 °C (230 °F) Resistance at +120 °C (257 °F) 6 7 8 9 10 11 12 13 14 15 16 17 Desc./Quantity 5.970 kOhm 3.750 kOhm 2.420 kOhm 1.600 kOhm 1.080 kOhm 0.
Norge GT 8v Electrical system BROWN PIN 5 and PIN 2 of the sensor should be restored. If the air temperature sensor error is displayed at the same time, this means that the grey cable common for both sensors is shorted to positive. • If shorted to negative, check sensor correct resistance: if resistance is null, replace the sensor; if resistance is correct, it means that the orange cable has ground connection: restore the cable harness.
Electrical system Norge GT 8v Air temperature In case of failure, temperature is set at 25 °C (77 °F) NAVIGATOR: ERRORS air temperature sensor P0110 - open circuit, shorted to positive / shorted to negative. Error cause • If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 14 of the BROWN connector.
Norge GT 8v Electrical system Lambda sensor Function In charge of telling the control unit whether the mixture is lean or rich. Operation / Operating principle The Marelli injection control unit reads and interprets a voltage generated by the difference in oxygen content between the exhaust fumes and the ambient. It does not require an external supply source but, in order to work properly, it should reach a high operating temperature: that is why there is a heating circuit inside.
Electrical system Norge GT 8v Error cause • Excessive voltage (battery voltage) has been detected at PINS 32 and 22 of the BLUE connector.
Norge GT 8v Electrical system and the Marelli control unit connector: If not OK, restore. If OK, check continuity between the BLUE connector PIN 22 and PIN 32 and restore the cable harness. ELECTRICAL ERRORS Right lambda sensor P0136 - Shorted to positive. Error cause • Excessive voltage (battery voltage) has been detected at PINS 21 and 31 of the BLUE connector.
Electrical system • Norge GT 8v An abnormal behaviour of the voltage at PIN 31 of the BLUE connector has been detected: the voltage, that should vary over time, keeps a constant value instead. Troubleshooting • check circuit continuity of the lambda sensor connector (PIN 1 PIN2) toward the probe: replace the lambda sensor if there is no continuity; if there is continuity, check the sensor connector and the Marelli control unit connector: If not OK, restore.
Norge GT 8v Electrical system Left injector P0201 - shorted to positive / shorted to negative / open circuit. Error cause • If shorted to positive: excessive voltage has been detected at PIN 28 of the BROWN connector. • If shorted to negative: no voltage has been detected.
Electrical system • Norge GT 8v 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.
Norge GT 8v Electrical system The auxiliary injection relay (no. 33 in the wiring diagram, placed under the saddle, left rear relay in the relay group attached to the fall sensor; 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. Disconnect the 4-way connector of the fuel pump to be able to hear the relay and injector activation.
Electrical system • Norge GT 8v If shorted to positive: excessive voltage has been detected at PIN 10 of the BROWN connector.
Norge GT 8v • Electrical system Check the sensor connector and the instrument panel connector (PIN 3): if they are not OK, restore. If OK, check continuity of the purple cable between the sensor connector and the instrument panel connector PIN 3: if not OK, restore the cable harness; if OK, replace the sensor. Oil pressure failure DSB 08 Error cause • An oil sensor fault is signalled when, with engine running, it is detected that the sensor circuit is closed.
Electrical system Norge GT 8v 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 there is, check cable continuity between the sensor connector and PIN 23 of the BROWN connector: if there is no continuity, restore the cable harness.
Norge GT 8v • Electrical system Indication on Navigator always No: check the correct position of the cable terminals on the sensor and the correct connection of the cables on the terminals. If they are not correct, restore the cable harness; if correct, disconnect the two terminals from the sensor and check continuity to ground of PIN 2 (cable harness side): if there is no continuity, restore the cable harness; if there is, replace the sensor.
Electrical system Norge GT 8v 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.
Norge GT 8v Electrical system continuity, restore the cable harness; if there is, with key set to KEY ON, check if there is 12V voltage at PIN 1.
Electrical system Norge GT 8v 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 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 panel; if there is approximately 12V, restore the cable harness (there is a short circuit in the battery).
Norge GT 8v • Electrical system sky blue/orange cable: 0V if engine kill in STOP; 12V if engine kill in RUN • red/black cable: Voltage 12V NAVIGATOR: STATUSES Run / stop switch Example value:Run/Stop DIAGNOSIS • Indication on Navigator always STOP: disconnect the connector and, with the switch set to RUN, check if there is continuity towards the switch of the green/blue (PIN 4) cables and the grey/sky blue (PIN 2) cable (sensor side): if there is not continuity, replace the sensor; if there is, check
Electrical system Norge GT 8v 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 Neutral sensor signal 24 Not used 25 Engine revolution sensor signal 26 Start-up relay control 27 Not used 28 Left cylinder injector control 29 Ignition potentiometer negative.
Norge GT 8v Electrical system 7 Immobilizer line 8 Not used 9 Not used 10 Not used 11 Oxygen probe negative control 1 (left) 12 Not used 13 Not used 14 Not used 15 Not used 16 K line (diagnosis) 17 Power supply from main relay 18 Not used 19 Not used 20 CAN - H line (ccm/instrument panel) 21 Lambda sensor 2 input (right)(-) 22 Lambda sensor 1 input (left)(+) 23 Not used 24 Vehicle speed signal input 25 Not used 26 Not used 27 "Engine stop" signal input 28 Ignition signal input 29 CAN - L line (ccm/instrum
Electrical system Norge GT 8v Dashboard PIN USE 1 + KEY 2 RIGHT TURN INDICATOR CONTROL 3 OIL PRESSURE SENSOR 4 HIGH BEAM LIGHT INPUT ELE SYS - 130 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten
Norge GT 8v Electrical system 56 SELECT 1 7 SELECT 2 8 FUEL LEVEL SENSOR 9 AIR TEMPERATURE SENSOR 10 11 + BATTERY 12 LEFT TURN INDICATOR CONTROL 13 RESET TURN INDICATORS 14 HAZARD 15 ANTITHEFT DEVICE LED (IF CONNECTED) 16 SELECT 3 17 SENSORS EARTH CONNECTION 18 GENERAL EARTH CONNECTION 19 GENERAL EARTH CONNECTION 20 GENERAL EARTH CONNECTION 21 + BATTERY 22 + BATTERY 23 LOW BEAM LIGHT RELAY ACTIVATION 24 25 HEATED HANDGRIP CONTROL 26 CAN L 27 CAN H 28 K LINE 29 ABS INPUT 30 AERIAL 1 31 32 33 34 RIGHT REAR
INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten
Norge GT 8v Engine from vehicle FRAME pos. 1 2 3 4 Description Plate to chassis fixing screw Plate to engine fixing nut Gear to chassis upper fixing pin Gear to chassis lower fixing pin Type M12x50 M10 M12 M12x270 Quantity 2 4 1 1 Torque 50 Nm (36.87 lbf ft) 80 Nm (59 lbf ft) 80 Nm (59 lbf ft) 80 Nm (59 lbf ft) Notes - Vehicle preparation Before removing the engine block, proceed as follows: • From the back, secure the vehicle with belts attached to a hoist.
Engine from vehicle Norge GT 8v Removing the engine from the vehicle • Disconnect the spark plug tubes. • Working on both sides disconnect the injector connectors. • Undo and remove the cable guide screw on the generator cover.
Norge GT 8v • Engine from vehicle Disconnect the engine temperature sensor connector • Disconnect the revolution sensor connector. • Disconnect the alternator connectors. • Disconnect the gear in neutral sensor connector.
Engine from vehicle • Unscrew and remove the stud bolt. • Disconnect the ground leads. • Disconnect the connectors of the start- Norge GT 8v er motor. • Unscrew 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.
Norge GT 8v • Engine from vehicle Disconnect the stand sensor connector and release it from the clamps. • Disconnect the oil pressure sensor connector. • Disconnect the oil temperature sensor connector. • Working from both sides, loosen the intake manifold clamps.
Engine from vehicle • Norge GT 8v Unscrew and remove the lower nut fixing the engine and collect the washer. • Remove the lower pin and collect the washer. • Remove the plates. CAUTION PERFORM THE OPERATIONS BELOW AIDED BY A SECOND OPERATOR. • Working on both sides, unscrew and remove the front screw and collect the washer. • Unscrew and remove the upper nut fixing the engine and collect the washer. • Remove the upper pin and collect the washer.
Norge GT 8v • Lower the engine completely. • Lift the rear part of the vehicle. • Release the front belts. • Hold the rear part of the vehicle, remove the chassis from the engine. 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 and a hoist. • From the front, secure the vehicle with belts attached to the handlebar and fixed to the work bench.
Engine from vehicle • Norge GT 8v Working on both sides, insert the washer and screw the screw without tighten it. • Working on both sides, place the plates • Working from the left side, fit the engine lower bolt with the washer. • From the opposite side, fit the washer and tighten the nut. • Working on both sides, tighten the front screw to the prescribed torque. • Fit the throttle body onto the intake manifolds.
Norge GT 8v • Engine from vehicle Connect the stand sensor connector and fix it to the engine with new clamps. • Connect the oil pressure sensor. • Connect the oil temperature sensor. • Fit the gearbox oil breather pipe.
Engine from vehicle • Fit the clutch control cylinder. • Tighten the three screws. • Connect the starter motor connectors. • Connect the ground leads and tighten Norge GT 8v the stud bolt. • Connect the neutral sensor connector.
Norge GT 8v • Connect the alternator connectors. • Connect the revolution sensor connec- Engine from vehicle tor. • Connect the engine temperature sensor connector. • Connect and adjust the throttle grip cable clearance.
Engine from vehicle • Norge GT 8v Place the swingarm 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. • Position the upper fairings and the fairing lug. • Install the complete exhaust. • Re-connect the battery. • Fit the saddle.
INDEX OF TOPICS ENGINE ENG Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten
Engine Norge GT 8v Gearbox Diagram Key: 1.
Norge GT 8v 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.Roller bearing 37.
Norge GT 8v 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.
Norge GT 8v • Engine Unscrew and remove the gearbox oil filler cap. • Place a container of suitable capacity under it, unscrew and remove the cap and then bleed all gearbox oil. • Loosen and turn the oil pipe joint on the sump. • Undo and remove the three screws.
Norge GT 8v Engine • Undo and remove the two screws. • Undo and remove the screw. • Remove the gearbox.
Norge GT 8v 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.
Norge GT 8v 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 using the specific tool. Specific tooling 05.91.25.
Norge GT 8v • 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.
Norge GT 8v Engine • 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. • Remove the forks and collect the shaft.
Norge GT 8v • 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.
Norge GT 8v Engine • Remove the gear of the sixth gear and collect the shoulder washer. • Remove the circlip. • Remove the gear of the third and fourth gears. • Remove the circlip and collect the shoulder washer.
Norge GT 8v • Engine Remove the gear of the fifth gear and collect the ball bearing cage. • Heat the shaft with a specific heater and remove the helical transmission gear. Removing the secondary shaft • Remove the transmission shaft. • Operate on the shaft from the grooved side. • Remove the shoulder washer.
Norge GT 8v Engine • Remove the gear of the second gear and collect the ball bearing cage and the shoulder washer. • Remove the circlip. • Remove the gear of the sixth gear. • Remove the circlip and collect the shoulder washer.
Norge GT 8v • Engine Remove the gear of the fourth gear and collect the ball bearing cage. • Remove the gear of the third gear and collect the ball bearing cage and the shoulder washer. • Remove the circlip. • Remove the gear of the fifth gear.
Norge GT 8v Engine • Remove the circlip, the shoulder washer and remove the gear of the first gear, collect the ball bearing cage. • Remove the bearing if necessary. See also Disassembling the gearbox 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.
Norge GT 8v Engine Checking the desmodromic drum Check gear drum for damage, scratches and wear and replace the desmodromic if necessary. Check the desmodromic segment «3» for damage and wear and replace it if necessary. Check the desmodromic bearing «4» for damage and cracks and replace it if necessary. Checking the forks NOTE THE FOLLOWING PROCEDURE IS VALID FOR ALL GEARBOX FORKS. • Check the transmission fork cam roller «1» and the transmission fork tooth «2» for damage, deformation and wear.
Norge GT 8v Engine primary shaft Fitting the secondary shaft NOTE TO REFIT, FOLLOW THE SAME INSTRUCTIONS AS FOR REMOVAL BUT IN REVERSE ORDER. REMEMBER TO REPLACE ALL SEALING RINGS, CIRCLIPS AND SAFETY RINGS PREVIOUSLY REMOVED. See also Removing the secondary shaft Assembling the gearbox NOTE TO REFIT, FOLLOW THE SAME INSTRUCTIONS AS FOR REMOVAL BUT IN REVERSE ORDER. REMEMBER TO REPLACE ALL SEALING RINGS, CIRCLIPS AND SAFETY RINGS PREVIOUSLY REMOVED.
Norge GT 8v Engine Disassembling the gearbox Gear selector GEAR INTERNAL CONTROLS pos. 1 Description Spring guide pin Type - Quantity 1 Torque 24 Nm (17.
Engine Norge GT 8v 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.
Norge GT 8v Engine ALTERNATOR pos. 1 2 3 Description Generator control pulley locking nut Generator upper fixing screw Generator lower fixing screw pos. 1 Description Timing system cover cap fixing screw Type M16 M8 M10x60 Quantity 1 1 1 Torque 80 Nm (59.00 lbf ft) 22 Nm (16.23 lbf ft) 30 Nm (22.13 lbf ft) Notes Loctite 243 - Torque 10 Nm (7.
Norge GT 8v Engine pos. 2 3 4 Description Timing system cover fixing screw Timing system cover fixing screw Generator cover fixing screw Type M8x55 M6x30 M6x16 Quantity 4 9 5 Torque 25 Nm (18.44 lbf ft) 12 Nm (8.85 lbf ft) 12 Nm (8.85 lbf ft) Notes - 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.
Norge GT 8v • Loosen the screw. • Loosen the nut and undo the set screw Engine so that the alternator slides down. • Completely loosen and remove the screw. • Remove the belt and the alternator with pulley.
Norge GT 8v Engine • Using a compressed air gun, unscrew and remove the nut and collect the spacer. • Remove the lower pulley. • Undo and remove the eight screws. • Undo and remove the two screws.
Norge GT 8v • Undo and remove the two screws. • Remove the alternator frame. • Remove the sealing ring if necessary. Engine See also Fuel tank Tensioning the belt • Remove the left fairing lug. • Undo and remove the two front fixing screws of the oil radiator. • Collect the spacers. • Undo and remove the five screws fixing the alternator belt cover. • Remove the oil radiator lower support bracket and the alternator belt cover.
Norge GT 8v Engine • Remove the generator belt cover by lightly loosening the oil radiator. • Loosen the screw. • Loosen the nut and undo the set screw so that the alternator slides down. • Using the belt tensioning tool, tension the belt to the prescribed torque. • Screw the set screw. • Tighten the lock nut. Specific tooling 020677Y Generator belt tensioner, lever for belt tensioning Locking torques (N*m) Belt tension 50 Nm (36.
Norge GT 8v Engine 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 05.92.72.30 Timing system cover sealing ring punch • 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.
Norge GT 8v Engine • Tighten the eight lower screws. • Operating diagonally and in stages, tighten the ten fixing screws on the alternator fitting. • 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.
Norge GT 8v • Position the screw and pre-tighten it. • 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.
Norge GT 8v Engine • Tighten the alternator fixing screws. • Place the alternator belt cover. • Tighten the five screws operating diagonally and in stages. Starter motor Removing the starter motor • Undo and remove the two screws and collect the washers.
Norge GT 8v • Engine Slide off the starter motor. Clutch side Disassembling the clutch Key: 1. Complete clutch 2. Clutch 3. Clutch bell 4. TCEI screw 5. Clutch plate 6. Sprocket 7. TCEI screw 8.
Norge GT 8v Engine 9. Ring 10.TE flanged screw 11.Conical washer 12.Bushing 13.Rod 14.Bushing 15.Intermediate body 16.Thrust bearing 17.Clutch control bowl 18.Thrust cylinder 19.Clutch control cylinder 20.TE flanged screw CLUTCH pos. 1 2 3 4 Description Clutch to crankshaft fixing screw Type - Quantity 6 Torque 42 Nm (30.98 lbf ft) Clutch external flange fixing screw on flywheel Start-up crown fixing screw on flywheel Clutch control cylinder fixing screw M7x16 - 6 6 3 20 Nm (14.
Norge GT 8v • Remove the complete gearbox. • Unscrew and remove the six screws. • Remove the start-up crown gear. • Remove the clutch bell and the friction Engine disc. • Remove the retainer ring. • Remove the clutch pressure plate.
Norge GT 8v Engine • Undo and remove the six screws and collect the belleville springs. • Remove the clutch plate. See also Removing the gearbox Checking the clutch actuator If the clutch is replaced, measure the length of the clutch control rod in order to use the correct rod. 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. • Fit the tool in the gearbox to determine the clutch control rod length.
Norge GT 8v 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.
Norge GT 8v 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.
Norge GT 8v Engine Heads CYLINDER HEAD COVERS pos. 1 2 Description Special cylinder head fixing screw Type - Quantity 8 Torque 8 Nm (5.90 lbf ft) Spark plug cover fixing screw M5x10 2 8 Nm (5.
Norge GT 8v Engine RIGHT CYLINDER HEAD pos. 1 2 2 3 4 5 6 Description Movable chain tensioner pad fixing screw Head tightening nut Type M10x1.25 Head tightening nut M10x1.25 Head tightening screws (chain compartment) M6x120 Plate locking screw and timing gear Timing cover fixing screw on the cylinder head M5x10 Camshaft support fixing screw - Quantity 1 4 Torque 20 Nm (14.75 lbf ft) 15 Nm (11.06 lbf ft) 4 2 1 2 6 42 Nm (30.98 lbf ft) 10 Nm (7.37 lbf ft) 30 Nm (22.13 lbf ft) 8 Nm (5.
Norge GT 8v Engine 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.Breather plate 20.TE flanged screw 21.
Engine Norge GT 8v 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.Pin 46.Timing system gear 47.
Norge GT 8v Engine Removing the head cover NOTE THE OPERATIONS DESCRIBED BELOW REFER TO ONE HEAD REMOVING ONLY BUT APPLY TO BOTH HEADS. • Disconnect the spark plug tube. • Unscrew and remove the four head cover fixing screws and collect the sealing O-rings. • 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.
Norge GT 8v Engine • Unscrew and remove the screw. • Remove the timing system upper gear bulkhead. For the right head: • Unscrew and remove the chain tensioner cap. • Remove the right chain tensioner. For the left head: • Unscrew and remove the screw and the washer. • Relief oil pressure from the left chain tensioner.
Norge GT 8v • 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. • Unscrew 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.
Norge GT 8v Engine • Collect the two head dowel pins. • Collect the gasket between the head 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.
Norge GT 8v • Remove the camshaft. • Remove the bowls from the cam cap, Engine 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.
Norge GT 8v 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.
Norge GT 8v Engine Checking the valve guides Use a punch to extract the valve guides from the heads. 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.
Norge GT 8v 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).
Norge GT 8v Engine Installing the rocker arms • Fit the camshaft. • Fit the two rods. WARNING MAKE SURE THAT THE NOTCH ON THE DIPSTICK BODY FACES THE ROCKING LEVER. • Place the two rocking levers in the cam tower seats. • Place the U-bolt on the rocking levers making sure the two reference pins match the seats on the cam tower. • Tighten the two screws operating diagonally and in stages.
Norge GT 8v Engine Installing the overhead camshaft Installing the overhead camshaft • Place the bowls in the cam tower, if those previously removed are refitted be careful not to interchange them. • Place the camshaft with the gear seat on the dowel side. • Place the U-bolt on the camshaft making sure the two reference pins match the seats on the cam tower. • Tighten the four screws operating diagonally and in stages.
Norge GT 8v Engine Timing TIMING SYSTEM CONTROL pos. 1 2 3 4 4 Description Control, timing system, shaft support flange fixing screw Bearing fixing screw Driving gears locking nut on the crankshaft Timing system driven gear locking nut Timing system driven gear locking nut Type M6x14 Quantity 2 Torque 8 Nm (5.90 lbf ft) Notes - M6x16 M25 M18 M18 1 1 1 1 10 Nm (7.37 lbf ft) 200 Nm (147.51 lbf ft) 25 Nm (18.44 lbf ft) 150 Nm (110.
Norge GT 8v Engine • 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. • Remove the service shaft closing cap. • 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.
Norge GT 8v Engine 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. • Insert the service shaft in its crankcase seat by sliding it through the two chains. • Fit each chain to the corresponding service shaft gear.
Norge GT 8v Engine • Tighten the cap with the two original TBEI screws. Installing sliders • Fit the crankshaft and the service shaft on the crankcase. • Fit the fixed chain sliders and tighten the fixing screws. • Tighten the chain caps with O-rings. • The operations related to the movable chain sliders are described in the cylinder fitting section.
Norge GT 8v 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 12.91.18.
Norge GT 8v 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.
Norge GT 8v • 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.
Norge GT 8v 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.
Norge GT 8v 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. Retainer ring 9. Cylinder base gasket 10.Stud bolt 11.Pin 12.Cylinder head gasket 13.Left cylinder 14.Washer 15.Chain tensioner cap 16.Washer 17.Left chain tensioner 18.
Norge GT 8v Engine CONNECTING ROD ASSEMBLY - CYLINDERS pos. 1 2 2 3 4 Description Thermal group fixing stud bolt Connecting rod screws Connecting rod screws Right hydraulic tensioner cover Left hydraulic tensioner cover Type M10x1.25 - Quantity 8 4 4 1 1 Torque 5 Nm (3.69 lbf ft) 40 Nm (29.50 lbf ft) 80 Nm (59.00 lbf ft) 42 Nm (30.98 lbf ft) 30 Nm (22.
Norge GT 8v Engine LEFT CYLINDER HEAD pos. 1 2 2 3 4 5 6 Description Movable chain tensioner pad fixing screw Head tightening nut Type M10x1.25 Head tightening nut M10x1.25 Head tightening screws (chain compartment) M6x120 Plate locking screw and timing gear Timing cover fixing screw on the cylinder head M5x10 Camshaft support fixing screw - Quantity 1 4 Torque 20 Nm (14.75 lbf ft) 15 Nm (11.06 lbf ft) 4 2 1 2 6 42 Nm (30.98 lbf ft) 10 Nm (7.37 lbf ft) 30 Nm (22.13 lbf ft) 8 Nm (5.
Norge GT 8v Engine • 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.
Norge GT 8v • Engine Mark the piston crown on the exhaust side so as to remember the refitting position. • 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.
Norge GT 8v 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.
Norge GT 8v 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.
Norge GT 8v 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.
Norge GT 8v 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.
Norge GT 8v 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. • Rotate the camshaft so that its pin is aimed towards the hole in the timing system chain. • Place the gear in the chain.
Norge GT 8v • 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. • Rotate the camshaft so that its pin is aimed towards the hole in the timing system chain. • Place the gear in the chain. • On the right camshaft pin, fit the hole marked with the letter "R" of the timing system gear.
Norge GT 8v 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.
Norge GT 8v 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.
Norge GT 8v 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).
Norge GT 8v 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.
Norge GT 8v 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.
Norge GT 8v 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 - 0.02180 in) Assembling the connecting rod • Lubricate the crankpin on which the connecting rods are to be fixed.
Norge GT 8v 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.
Norge GT 8v • 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. Specific tooling 12.
Norge GT 8v 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. Lubrication LUBRICATION SYSTEM pos.
Norge GT 8v Engine OIL RADIATOR pos. 1 2 3 Description Solenoid valve to radiator fixing screw Radiator fixing pin on the grille Radiator to grille fixing screw Type M5x60 M5 M5 Quantity 3 1 1 Torque 4 Nm (2.95 lbf ft) 4 Nm (2.95 lbf ft) 4 Nm (2.
Norge GT 8v Engine OIL PUMP pos. 1 2 3 Description Oil pump fixing screw Oil pump driven gear locking nut Oil pressure valve cap pos.
Norge GT 8v Engine OIL SUMP COMPONENTS pos. 1 2 3 4 5 6 Description Cover on the flange under the crankcase Oil filter joint Oil sump pipe Oil filter Rose pipe fixing screw Maximum pressure valve cover Type M6 M18 Quantity 1 1 1 1 1 Torque 40 Nm (29.50 lbf ft) 10 Nm (7.37 lbf ft) 20 Nm (14.75 lbf ft) 15 Nm (11.06 lbf ft) 10 Nm (7.37 lbf ft) 40 Nm (29.
Engine Norge GT 8v Conceptual diagrams Key: 1. Oil cooling 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.
Norge GT 8v Engine The oil pump is operated by the gear (10) which receives the motion directly from the crankshaft. The gear (10) is mounted on the shaft (8), on which two rotors are fitted: one for engine cooling (7) and another for lubrication (6). Cooling: The rotor (7) takes in oil from the sump through the filter (12); the oil is sent to the radiator (1) through the hoses (3). Oil passes through the radiator (1) dispersing part of the heat and reaches the heads through the hoses (2).
Norge GT 8v Engine • 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. • Collect the washer. • Remove the oil pump driven gear.
Norge GT 8v • Engine Remove the gasket between the crankcase and the oil pump. See also 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. • Place the driving pin on the oil pump shaft.
Norge GT 8v Engine • 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. • Insert the joint in the oil pump.
Norge GT 8v • Engine Fit the nipple with the gasket on the 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 01.92.91.00 Wrench for removing the cover on sump and filter • Unscrew and remove the oil level plug and collect the O-Ring.
Norge GT 8v Engine • Undo and remove the four screws. • Remove the flange. • Undo and remove the two screws. • Remove both filters.
Norge GT 8v • Unscrew and remove the plug. • Remove the thermostatic valve. • Unscrew and remove the pressure re- Engine lief valve plug.
Norge GT 8v 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. • Tighten the thermostatic valve plug.
Norge GT 8v • Engine Place a new gasket between the crankcase and the flange. • Fit the flange. • Fix the flange with the four screws. • Fit the lubrication oil intake filter. • Check that the O-rings are fitted on the oil pump. • Fit the cooling oil intake filter.
Norge GT 8v Engine • 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. • Place the oil sump. • Tighten the fourteen screws to the prescribed torque. • Add engine oil up to the correct level.
INDEX OF TOPICS POWER SUPPLY P SUPP Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten
Norge GT 8v Power supply FUEL SUPPLY SYSTEM pos. 1 2 Description Fuel pump support fixing screw to the tank Fuel pump support fixing screw to the tank pos. 1 2 Description Intake pipe fixing screw Flange fixing screw on the throttle body Type M5x20 M5x16 Quantity 2 4 Torque 5 Nm (3.68 lbf ft) 6 Nm (4.42 lbf ft) Notes - Torque 10 Nm (7.37 lbf ft) 6 Nm (4.
Norge GT 8v Power supply Circuit diagram Key: 1. Full fuel tank 2. Fuel pipe 3. Throttle body 4. Joint 5. Three-way joint 6.
Power supply Norge GT 8v 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.
Norge GT 8v Power supply 12. Lambda probe 13. Side stand 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 Navigator tool to the diagnosis connector and to the vehicle battery.
Power supply • Turn on the scanner. • Screw the joints connecting the vacu- Norge GT 8v ometer pipes on the inlet pipe holes. • Connect the vacuometer pipes to the relative joints. • Set the key to ON. • 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.
Norge GT 8v Power supply difference between the two pressures is 1 cm Hg (1.33 kPa) maximum. If this condition is detected: • take 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. 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.
Norge GT 8v Power supply Injection system ECU INFO screen page This screen page shows general data regarding the control unit, for example software type, mapping, control unit programming date INFO ECU SCREEN PAGE Specification Mapping Desc./Quantity - PARAMETERS screen page This screen page 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.
Norge GT 8v Power supply Specification Lambda integrator Desc./Quantity When the control unit uses the lambda probe signal (see the 'Lambda' parameter on the 'Statuses' screen page) this value should be close to 0%.
Norge GT 8v Power supply ACTIVATION screen page This screen page is used to delete errors in the control unit memory and to activate some systems controlled by the control unit. ACTIVATION Specification Left coil Right coil Left injector Right injector Error clearing Desc./Quantity operation for 2.5 m, 5 times operation for 2.5 m, 5 times Operation for 4 m, 5 times Operation for 4 m, 5 times By pressing the 'enter' button, the stored errors (MEM) become part of the historical data (STO).
Norge GT 8v Power supply Specification Lambda probe Desc./Quantity Possible short circuit on the earth lead, battery or open circuit or plausibility: recovery function hardly noticeable for customer. 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.
INDEX OF TOPICS SUSPENSIONS SUSP Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten
Norge GT 8v Suspensions Front FRONT WHEEL pos. 1 2 3 4 Description Front wheel spindle nut Front brake disc fixing screw Front tone wheel fixing screw Front ABS sensor fixing screw Type M25 M8x20 M6 Quantity 1 12 5 1 Torque 80 Nm (59.00 lbf ft) 25 Nm (18.44 lbf ft) 4 Nm (2.95 lbf ft) 10 Nm (7.37 lbf ft) Notes Loctite 243 Loctite 243 - Removing the front wheel • Unscrew the speed sensor screw, release the cable harness from the clamps. • Remove the speed sensor.
Suspensions • Norge GT 8v Unscrew the screws fixing the front brake callipers and remove them from their seat. • Support the front part of the vehicle. • Remove the nut fixing the wheel pin. • Collect the sealing washer. • Loosen the screws on the wheel pin terminals. • Remove the wheel pin by inserting a screwdriver in the holes on the pin.
Norge GT 8v • Suspensions During extraction, support the wheel and then remove it. • Collect the spacer from the front wheel right side. Installing the front wheel • Position the wheel together with the right side spacer. • Insert the pin • Screw the screws of the clamp (nut side) to lock the rotation of the wheel axle.
Suspensions • Norge GT 8v Insert the sealing washer onto the wheel axle. • Tighten the wheel axle fixing nut to the specified torque • Make sure that the stanchions are aligned by working with the fork. • Tighten the terminal screws that lock the wheel pin to the prescribed torque. • Fit the brake callipers tightening the fixing screws to the prescribed torque. CAUTION AFTER FITTING THE BRAKE CALLIPERS, OPERATE THE FRONT BRAKE LEVER SEVERAL TIMES • Fit the speed sensor.
Norge GT 8v • Suspensions Fit the front mud guard. Handlebar HANDLEBAR AND CONTROLS pos. 2 2 3 4 Description Half-handlebar lower fixing screw on the upper steering yoke Half-handlebar upper fixing screw on the upper steering yoke Handlebar pipe fixing screw on the half-handlebar Counterweight fixing screw Type M8x25 Quantity 2 Torque 25 Nm (18.44 lbf ft) Notes - M8x25 STAINLESS STEEL M8x30 4 20 Nm (14.75 lbf ft) Loctite 243 2 18 Nm (13.27 lbf ft) Loctite 243 M6x70 2 10 Nm (7.
Norge GT 8v Suspensions Front fork FRONT FORK pos. 1 2 3 Description Wheel axle locking screw on the fork leg Piston fixing screw to the sleeve Fork cap Type M6 M10x35 - Quantity 4 2 2 Torque 10 Nm (7.37 lbf ft) 50 Nm (36.87 lbf ft) 20 Nm (14.
Norge GT 8v Suspensions STEERING YOKE pos. 1 2 3 4 5 6 Description Fork stanchion fixing screw on the upper plate Fork stanchion fixing screw on the lower plate Upper yoke fixing cap Headstock ring nut Headstock counter-lock ring Pipe stop plate fixing screw to the steering base Type M8x30 M8x25 M29 M35 M35 M6x18 Quantity 2 4 1 1 1 1 Torque 25 Nm (18.44 lbf ft) 25 Nm (18.44 lbf ft) 100 Nm (73.76 lbf ft) 40 Nm (29.50 lbf ft) 10 Nm (7.37 lbf ft) Notes Manually screw - Diagram KEY: 1. Screw 2.
Suspensions Norge GT 8v 12. Pin 13. Complete cover 14. Counter spring 15. Complete pumping member 16. Ring 17. Lower bushing 18. Stem 19. Preload tube 20. Spring 21. Locking ring 22. Bushing 23. Nut 24. Fifth wheel 25. O-Ring 26. Cap body 27. O-Ring 28. Rigging pin Removing the fork legs • Undo the screws fixing the front mudguard and remove it. • Hold the motorcycle front section. • Remove the front wheel. • Unscrew the speed sensor screw, release the cable harness from the clamps.
Norge GT 8v Suspensions front wheel • Unscrew the fixing screws of the front brakes callipers and remove them from their seats. • Support the stanchion and loosen the screws on the upper and then the lower plate. See also Removing the front wheel • Remove the fork stem.
Suspensions Norge GT 8v Draining oil To drain out the oil follow these operations: • Remove the fork. • Unscrew the complete upper closing cap. Pay attention to the possible thrust that the spring can cause to the loosened cap. • Be careful not damage the O-Ring during extraction. • Press the stem inside the wheel holder sleeve. • Remove the spring. • Be careful not damage the O-Ring during extraction. • Press the stem inside the wheel holder sleeve. • Remove the spring.
Norge GT 8v Suspensions NOTE FOR EASY DRAINAGE OF THE OIL INSIDE THE PUMPING MEMBER ROD, PRESS THE STEM IN THE WHEEL HOLDER SLEEVE TO PUMP OIL OUT. • Carefully check each part of the stem and make sure that there are no damaged elements. • If there are no damaged or worn elements, refill the stem; otherwise, replace the damaged elements. Disassembling the fork • Drain out all the oil in the stem. • Block the wheel holder sleeve with a vice.
Suspensions • Norge GT 8v Remove the locking ring inside the sleeve using a thin screwdriver. CAUTION BE CAREFUL NOT TO DAMAGE THE SLEEVE RIM. • Slide off the stem from the wheel holder sleeve together with the lower bushing, sealing ring, cap, upper bushing and the entire pumping member. NOTE WHEN REMOVING THE STEM FROM THE WHEEL HOLDER SLEEVE SOME PARTS MAY REMAIN INSIDE THE SLEEVE.
Norge GT 8v Suspensions Checking the components Stem Check the sliding surface for scorings and/or scratches. These scorings can be eliminated by rubbing them with wet sandpaper (grain 1). If the scorings are deep, replace the stem. Use a dial gauge to check that the stem bending is below the limit value. If over the value, replace the stem. CAUTION A BENT STEM SHOULD NEVER BE STRAIGHTENED BECAUSE ITS STRUCTURE WOULD BE WEAKENED AND USING THE VEHICLE MAY BECOME DANGEROUS.
Suspensions Norge GT 8v REMOVE ANY IMPURITY IN THE BUSHINGS, TAKING CARE NOT TO SCRATCH THEIR SURFACE. Replace the following components with new ones: • seal ring; • dust gaiter; • O-Ring on the cap. Reassembling the fork CAUTION ALL COMPONENTS MUST BE CAREFULLY WASHED AND DRIED WITH COMPRESSED AIR BEFORE REFITTING.
Norge GT 8v • Suspensions Carry out any necessary service operation. • On the stem, fit the entire pumping unit together with counter spring and ring. • Check that the upper guide bushing is fitted on the wheel holder fork leg. • Insert the lower sliding bushing in the seat on the stem. • Refit the stem in the wheel holder fork leg pressing it until it stops. • Screw the bottom screw and tighten it to the prescribed torque.
Suspensions • Norge GT 8v Insert the cap and the well lubricated sealing ring in the stem. • Use a suitable inserting tool to push the sealing ring in the fork leg until it stops. • Fit the locking ring. • Fit the dust scraper.
Norge GT 8v Suspensions Filling oil • Place the sleeve upright in a vice fitted with protection jaws. • Compress the sleeve in the stanchion. • Pour part of the fork oil into the sleeve. • Wait some minutes until the oil fills all the ducts. • Pour the remaining oil. • Pump out oil a few times. • Measure the air gap between the oil level and the rim. THE SLEEVE MUST BE PERFECTLY UPRIGHT IN ORDER TO MEASURE THE CORRECT OIL LEVEL. THE OIL LEVEL MUST BE THE SAME IN BOTH STEMS.
Suspensions • Norge GT 8v Place the cap on the bearing tube taking care not to damage the O-ring. • Then, tighten the cap to the prescribed torque. Installing the fork legs • Insert the stanchion in position. • Insert the wheel pin so that the stems are aligned. • Tighten the screws on the fork plates to the prescribed torque. • Slide off the wheel axle.
Norge GT 8v Suspensions Steering bearing STEERING YOKE pos. 1 2 3 4 5 6 Description Fork stanchion fixing screw on the upper plate Fork stanchion fixing screw on the lower plate Upper yoke fixing cap Headstock ring nut Headstock counter-lock ring Pipe stop plate fixing screw to the steering base Type M8x30 M8x25 M29 M35 M35 M6x18 Quantity 2 4 1 1 1 1 Torque 25 Nm (18.44 lbf ft) 25 Nm (18.44 lbf ft) 100 Nm (73.76 lbf ft) 40 Nm (29.50 lbf ft) 10 Nm (7.
Suspensions Norge GT 8v Adjusting play • Remove the two Side covers removal of the control panel by unscrewing the two fixing screws and releasing the internal peg. • Unscrew the screws on the cable retainer plate. • Operating on both half-handlebars, remove the lower fixing screw to the fork plate. • Remove the upper plate closing cap. • Unscrew and remove the fixing screws on both sides of the upper plate.
Norge GT 8v • Suspensions Unscrew the headstock fixing bolt to the upper plate. • Collect the shim washer. • Unscrew and remove the four fixing screws of the half-handlebar to the plate. • Remove both half-handlebars, leaving them tied to the cables.
Suspensions • Norge GT 8v Rivet the safety washer on the headstock. CAUTION UPON REFITTING REPLACE THE SAFETY WASHER WITH A NEW ONE. • Undo the upper ring nut CAUTION UPON REFITTING TIGHTEN THE UPPER RING NUT MANUALLY AND THEN FORCE IT SLIGHTLY UNTIL THE NOTCHES ARE ALIGNED WITH THE RING NUTS. Specific tooling 020884Y 46 mm wrench for steering ring nut • Remove the safety washer. • Adjust the steering bearing preload with the special tool. NOTE GET THE ADEQUATE SPECIAL TOOL.
Norge GT 8v Suspensions Shock absorbers REAR SUSPENSION pos. 1 2 3 4 5 Description Shock absorber to chassis fixing screw Shock absorber to double connecting rod fixing screw Shock absorber to single connecting rod fixing screw Double connecting rod to swingarm fixing screw Screw fastening single linkage to chassis Type M10x80 M10x82 Quantity 1 1 Torque 50 Nm (36.87 lbf ft) 40 Nm (29.50 lbf ft) Notes - M10x95 1 50 Nm (36.87 lbf ft) - M10x47 1 50 Nm (36.87 lbf ft) - M10x85 1 50 Nm (36.
Norge GT 8v Suspensions Standard rear shock absorber setting is adjusted to suit most high and low speed riding conditions, to transport the rider plus luggage. However, this set can be modified for specific needs according to vehicle use. BEFORE MAKING ANY ADJUSTMENTS, WAIT FOR THE ENGINE AND SILENCER TO COOL COMPLETELY. ADJUSTMENTS Regular adjustment (standard): - rider only. Half load adjustment: - (for example, rider with passenger or with luggage). Maximum load adjustment: - (e.g.
Norge GT 8v Suspensions NOTE (2) IF FITTED. Removing • Remove the saddle. • Remove the side fairings. • Screw in the preloading knob until reaching the end of the stroke. • Remove the preloading knob by unscrewing the central screw. See also Bodywork • Unscrew the connecting rod screws and remove the pin.
Suspensions • Norge GT 8v Remove the lower screw of the single shock absorber. CAUTION BEFORE REMOVING THE LOWER SCREW OF THE SINGLE SHOCK ABSORBER, HOLT THE SWINGARM-WHEEL UNIT. • Remove the upper screw of the single shock absorber. • Remove the single shock absorber, being careful not to damage the motorbike components.
INDEX OF TOPICS CHASSIS CHAS Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten
Norge GT 8v Chassis Swinging arm REAR SWINGARM pos. 1 2 3 4 Description Swingarm clamp fixing screw on the bushing 2 - Swingarm fixing screw on the transmission housing Swingarm pin on the swingarm Preloading bushing to the swingarm pin Type M6x25 M10x35 Quantity 2 4 Torque 10 Nm (7.37 lbf ft) 50 Nm (36.87 lbf ft) Notes - M12 M25 1 1 60 Nm (44.25 lbf ft) 10 Nm (7.37 lbf ft) - Removing • To remove the swingarm, first remove both footrest supporting plates and the exhaust silencer.
Norge GT 8v • Engage the first gear. • Unscrew and remove the four screws, Chassis collecting the spacers and the dust protection ring. • Remove the rear wheel. • Unscrew and remove the nut fixing the reaction rod. • Remove the screw. • Fix the reaction rod to the chassis with a clamp. • Remove the clamp from the dust guard cap.
Norge GT 8v Chassis • Loosen the two swingarm 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 clamps on the chassis. • Loosen the ring nut. Specific tooling 14.91.26.
Norge GT 8v • Chassis Helped by a second operator, remove the pin and remove the swingarm together with the 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.
Norge GT 8v Chassis • Working from both sides, grease the cardan shaft cables with the recommended product from the recommended products table. • Block the swingarm, insert the universal joint, align the holes and, at the same time, helped by a second operator, insert the pin completely. • Tighten the swingarm pin. • Use the suitable box-spanner to tighten the ring nut. Specific tooling 14.91.26.
Norge GT 8v • Place the reaction rod into its seat. • Insert the screw. • Screw the nut fixing the reaction rod. • Place the connecting rod assembly on Chassis the swingarm. • 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.
Norge GT 8v Chassis • Place the rear wheel on the swingarm. • Tighten the four screws with their spacers and the dust-protection ring. • Place the cover. • Place the rear brake calliper on the disc and the brake pipe on the swingarm. 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.
Norge GT 8v • Chassis Remove the transmission casing sliding off the universal joint. Checking Casing unit removal Remove the cover (20). Remove the plug (3) to drain out the oil.
Chassis Norge GT 8v Lift the cap (10). Remove the clamps (9) and (11). Remove the cap (14). Remove the screws (16). Collect the ring (15).
Norge GT 8v Chassis Remove the screws (7). Remove the casing (4). Remove the clamp (12). Remove the cap (14). Collect the ring (13).
Chassis Norge GT 8v Remove the support unit (8). 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. Heat the casing.
Norge GT 8v Chassis Insert the support group in the casing. Assemble the cap and the ring. Fit the cap on the support. Fit the clamp. Screw the clamp with the specific pliers.
Chassis Norge GT 8v 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. Fit the casing. Remove the two dowel pins.
Norge GT 8v Chassis Assemble the fixing screws (7). Tighten the screws (7) to the prescribed torque. Remove excessive sealant. Assemble the ring to the casing. Tighten the fixing screws to the prescribed torque. Fit the cap with the washer. Screw the cap to the prescribed torque.
Chassis Norge GT 8v 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. Fit the cap in its seat.
Norge GT 8v Chassis Gruppo asse ruota Removal Remove the bearing from the wheel axle with a suitable extractor. Turn the unit over. Remove the bearing from the wheel axle with a suitable extractor. FITTING Heat the bearings to 100°C (212 °F). Assemble the bearings to the wheel axle.
Chassis Norge GT 8v Turn the unit over. Assemble the bearings to the wheel axle. Pinion unit 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.
Norge GT 8v Chassis Assemble the sealing ring (3) to the ring nut (2) with the buffer CA715855 (see Fig.1) and a hammer. Lubricate the sealing ring (3). Assemble the ring nut (2). Tighten the ring nut (2) with the special spanner (s4) to the prescribe torque.
Chassis Norge GT 8v Insert the stop ring (1) in the ring nut (2) in the indicated direction. Assembly position of the stop ring (1). CAUTION MAKE SURE THE STOP RING IS IN ITS SEAT.
Norge GT 8v Chassis Support unit Removal Remove the bushing (1) with a punch. Turn the support (5) over and remove the other bushing (8). Remove the sealing rings (2) and (7) with a screwdriver. Remove the stop rings (3) and (6) from the support (5) with suitable pliers. NOTE THIS OPERATION DESTROYS THE SEALING RING.
Chassis Norge GT 8v Remove the ball joint (4) with a suitable buffer and a rubber hammer. FITTING Fit the stop ring (6) in the support (5) with suitable pliers. Turn the support (5) over. Assemble the ball joint (4) with the buffer and a rubber hammer. Fit the stop ring (3) in the support (5) with suitable pliers.
Norge GT 8v Chassis Manually assemble the new sealing rings (2) and (7). Assemble the bushing (1). Drive the bushing (1) in with a plastic hammer. Turn the support (5) over and assemble the other bushing (8). TROUBLESHOOTING Possible Cause 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 the sealing ring and the casing 2.
Norge GT 8v Chassis Installing • Insert the transmission casing on the swingarm 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.
Norge GT 8v 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. • Place the speed sensor and fasten the cable harness with the clamps. Exhaust EXHAUST SYSTEM pos.
Norge GT 8v Chassis • Release and remove the spring between the exhaust end and the catalytic converter. • Loosen the clamp between the exhaust end and the catalytic converter. • Unscrew and remove the muffler fixing nut and collect the screw and the bushing. • Remove the exhaust end. Removing the manifold - tail pipe • Remove both exhaust manifolds. • Remove the exhaust end. • Unscrew and remove the anti-vibration rubber ring fixing screws on both sides.
Norge GT 8v Chassis Removing the tail pipe Removing the exhaust manifold CAUTION THE ENGINE AND THE EXHAUST SYSTEM COMPONENTS CAN GET VERY HOT AND REMAIN SO FOR SOME TIME EVEN AFTER THE ENGINE IS TURNED OFF. WEAR INSULATING GLOVES BEFORE HANDLING THESE PARTS OR WAIT UNTIL THE ENGINE AND THE EXHAUST SYSTEM COOL DOWN. NOTE THE FOLLOWING PROCEDURE IS VALID FOR BOTH MANIFOLDS. • Disconnect the Lambda sensor connector. • Cut the clamp indicated.
Norge GT 8v Chassis • Loosen the clamp. • Remove the exhaust manifold. Removing the lambda sensor • Unscrew and remove the lambda sensor. • Remove the exhaust manifold.
Norge GT 8v Chassis Engine oil cooler OIL RADIATOR pos. 1 2 3 Description Solenoid valve to radiator fixing screw Radiator fixing pin on the grille Radiator to grille fixing screw Type M5x60 M5 M5 • Remove the right side fairing. • Operating from both sides of the lug, Quantity 3 1 1 Torque 4 Nm (2.95 lbf ft) 4 Nm (2.95 lbf ft) 4 Nm (2.95 lbf ft) Notes - unscrew the front and lower screws.
Norge GT 8v Chassis • Unscrew the two right fairing lug side fixing screws. • Remove the right fairing lug and recover the internal bushing. • Working on the left side, unscrew and remove the left side fairing lower fixing screw.
Norge GT 8v • Chassis Unscrew and remove the side fixing screw of the left fairing lug. • Remove the left fairing lug. • Drain the engine oil. • Undo and remove the two front fixing screws of the oil radiator. • Collect the spacers. • Disconnect the fan motor connector and release the cables from the indicated clamp. • Unscrew the joints of the oil pipe on the radiator. • Remove the radiator oil together with the fan and duct.
Chassis Norge GT 8v See also Replacement Side fairings CHAS - 306 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten
INDEX OF TOPICS BRAKING SYSTEM BRAK SYS Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten
Norge GT 8v Braking system BRAKE SYSTEM pos. 1 2 3 Description Brake pipe slot screw on the pump Joint with brake pipes retainer bleeding on the calliper Brake pipes joint on the ABS hydraulic unit Type M10 M10 Quantity 2 3 Torque 25 Nm (18.44 lbf ft) 25 Nm (18.44 lbf ft) Notes - - 4 25 Nm (18.
Norge GT 8v Braking system ABS Key: 1. ABS ECU control unit 2. Front ABS sensor 3. Rear ABS sensor 4. Battery 5. ECU 6. Instrument panel 7. K line (diagnosis) 8. Key 9.
Braking system • PIN 2 - PCC1 - Vehicle identification ground connection • PIN 3 - Speed signal to the ECU control unit • PIN 4 - IGN - Key • PIN 7 - ABS OFF - ABS Deactivation button • PIN 8 - WL.
Norge GT 8v Braking system Operating diagram ABS functional diagram key 1. Front system circuit 2. Front brake pump 3. Front brake lever 4.
Braking system Norge GT 8v 5. Rear brake pump 6. Rear brake pedal control 7. ABS CONTROL UNIT 8. Rear brake calliper 9. Front calliper (2 callipers) 10.Front brake circuit intake solenoid valve (normally open) 11.Humidifier 12.Rear brake circuit intake solenoid valve (normally open) 13.Rear brake exhaust circuit solenoid valve (normally closed) 14.Rear/front brake circuit low pressure accumulator 15.Front brake exhaust circuit solenoid valve (normally closed) 16.DC electric motor 17.
Norge GT 8v Braking system D - Pressure restored: by opening the inlet valve (10-12) momentarily, the pressure of the callipers (8-9) is increased until maximum deceleration is reached. Then, the system gives the control over the braking back to the rider. E - If the wheel does not reach complete grip, the system continues operating as before until complete grip is obtained or until the vehicle stops. An error can be detected if the duration of the pressure reduction phase exceeds the pre-set time limit.
Braking system Norge GT 8v - the ABS system intervenes by releasing pressure from the calliper until the wheel turns again at the same speed of the other wheel; it is not possible to brake for an instant. - if the speed difference lasts long, the system may detect an error and deactivates the ABS system. As a consequence, the system works as any regular braking system.
Norge GT 8v • Braking system Once riding, the ABS system will be reactivated only after riding faster than 5 km/h (3.1 mi/h) and the ABS warning light (5) on the instrument panel (4) turns off. CAUTION IF THE ABS SWITCH IS PRESSED FOR MORE THAN TEN SECONDS, THE SYSTEM DETECTS A FAILURE. TO ACTIVATE THE ABS SYSTEM AGAIN TURN THE IGNITION SWITCH TO "OFF" AND THEN TO "ON". IN CASE OF FAILURE OR WITH ABS DISCONNECTED, THE VEHICLE OPERATES AS IF IT DID NOT HAVE THIS SYSTEM.
Norge GT 8v Braking system The system operates perfectly just as any other braking system without ABS. The detection of malfunctions may require more or less time according to the type of failure. Error detection logic foresees that for the errors to be diagnosed one or more conditions must persist within a given time. If during this given time one of the conditions is missing but then it comes back, the timer is reset and the system is no longer able to diagnose the error.
Norge GT 8v Braking system ECU INFO screen page This screen page shows general data regarding the control unit, for example software type, mapping, control unit programming date INFO ECU SCREEN PAGE MOD2 Characteristic Value/example Vehicle manufacturing date Chassis number Software version Vehicle code Vehicle identification according to the status of Pin 2 and 15 of the ABS control unit connector Unit of measure ment Norge / Stelvio Norge / Stelvio Notes The vehicle code stored in the control uni
Norge GT 8v Braking system ACTIVATION screen page This screen page is used to delete errors in the control unit memory and to activate some systems controlled by the control unit.
Norge GT 8v Braking system ERRORS Characteristic Front speed sensor: 5D90 electric malfunction Front speed sensor: 5D91 the signal works irregularly Front speed sensor: 5D92 the signal decreases periodically Front speed sensor: no signal or speed measured too low in relation to the rear wheel 5D93 Front speed sensor: 5D94 no acceleration after pressure reduction Front speed sensor: 5D95 excessive measured speed Rear speed sensor: 5DA0 electric malfunction Rear speed sensor: 5DA1 the signal works irregul
Norge GT 8v Braking system SETTINGS screen page This screen page is used to adjust some control unit parameters. ADJUSTMENTS Characteristic Value/example Coding (1) Unit of measure ment Notes Used for re-coding the control unit or coding a new one. Vehicle identification is done according to the connection of PINS 2 and 15 of the ABS control unit connector and is stored in the control unit memory. The identification can be read in the INFO ECU screen page in the line: Vehicle code.
Norge GT 8v • Braking system Undo and remove the two control unit fixing screws. See also Fuel tank • Disconnect the ABS control unit connector. • Remove the ABS control unit. INSERTION PROCEDURE OF ABS CONTROL UNIT CONNECTOR • Check the initial position of the lever that couples the connector.
Braking system • Norge GT 8v When the connector is fully inserted, the distance between the connector and the ABS control unit must be 7.5 mm (0.29 in). • If the initial position of the connector and the driving lever is not that shown in fig. 1, the connector will not be properly coupled and the distance measured will be greater (12 mm approx. (0.47 in)). In this case repeat the operation as described in the two previous points.
Norge GT 8v Braking system 0.3 - 2.00 mm (0.012 - 0.079 in) for the front one; 0.3 - 2.00 mm (0.012 - 0.079 in) for the rear one; CAUTION IF A VALUE BEYOND THE TOLERANCE RANGE IS MEASURED, REPLACE THE SENSOR (1) AND/OR THE TONE WHEEL (2) AND REPEAT THE CHECKS; MAKE SURE THAT THE VALUES ARE WITHIN THE TOLERANCE LIMITS. TONE WHEELS (2) CLEANING It is important to check that all the tone wheels (2) are always clean. Otherwise,: gently remove any possible dirt deposits with a cloth or metal brush.
Norge GT 8v Braking system REAR BRAKE CALLIPER pos. 1 Description Rear brake calliper fixing screw Type M10 Quantity 2 Torque 50 Nm (36.87 lbf ft) Notes - Torque 50 Nm (36.87 lbf ft) Notes - Front brake calliper FRONT BRAKE CALLIPERS pos. 1 Description Front brake calliper fixing screws Type M10 Quantity 4 Rear brake disc Disc Inspection CAUTION THE BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE SPECIFICATIONS OF THE SYSTEM.
Norge GT 8v • Braking system The following operations are to be carried out with brake disc fitted on the wheel. • Check the disc for wear by measuring the minimum thickness with a micrometer in different points. If the minimum thickness, even in a single point of the disc, is less than the minimum value, replace the disc. Disc thickness minimum value: 4.5 mm (0.
Braking system Norge GT 8v 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 LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS.
Norge GT 8v Braking system Removal • Undo and remove the two screws. • Remove the brake calliper from the disc. • Turn the pin and pull out the split pin. • Remove the split pin. • Remove the pin. • Extract one pad at a time. CAUTION AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS. • Insert two new pads, placing them so that the holes are aligned with the calliper holes.
Braking system • Insert the pin. • Place the split pin. • Check the brake fluid level in the res- Norge GT 8v ervoir. 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. • Insert the brake calliper into the disc by screwing in the two screws.
Norge GT 8v Braking system Bleeding the braking system VEHICLE PREPARATION • It is important to check that there is always enough brake fluid in the reservoir. • Using a bleed device facilitates these operations while, in the meantime, the "Brake fluid replacement" operations are performed. • In this case, the bleed process must be accompanied by further pedal strokes and with the bleed device connected (about 5 for each wheel circuit).
Braking system Norge GT 8v REPLACE THE ABS CONTROL UNIT VEHICLE PREPARATION • Connect the bleed bottle to the bleed screws of the front and rear callipers and open it. • Fully press down the lever and the brake pedal and fix them into position with the respective locking devices. • Close the bleed screws of the front and rear callipers and remove the bleed bottle. • Remove the damaged ABS control unit.
Norge GT 8v Braking system • Check the stroke and the sensitivity of both the lever and the brake pedal. • If, after bleeding, the pedal or the lever stroke is too long, check that there are no leaks in the braking system and if everything is ok, continue bleeding operations using Navigator as described. • Detach the bleed hoses and close the bleed screws again to the correct tightening torque.
Braking system Norge GT 8v BLEEDING SYSTEM WITH NAVIGATOR This type of bleeding has to be carried out if after all the checks the brake lever and the pedal are still spongy. The operations described here are valid for both systems even though the description refers to the front system. FRONT • With Navigator properly connected, select the function "FRONT BRAKE BLEEDING PROCEDURE". • The pump starts rotating.
Norge GT 8v Braking system REGULAR AIR BLEEDING SYSTEM • Remove the rubber protection cover from the bleed valve. • Insert the transparent plastic pipe in the front brake calliper bleed valve and slide the other end of this pipe in a container to collect the fluid. • Remove the front brake fluid reservoir cap. • Quickly press and release the front brake lever several times and then keep it fully pressed. • Loosen the bleed valve 1/4 of a turn so that the brake fluid flows into the container.
Braking system Norge GT 8v WITH THE NECESSARY QUANTITY OF BRAKE FLUID. CHECK THAT, DURING THE OPERATION, THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR. REGULAR AIR BLEEDING SYSTEM • Remove the rubber protection cover from the bleed valve. • Insert the transparent plastic pipe in the front brake calliper bleed valve and slide the other end of this pipe in a container to collect the fluid. • Remove the front brake fluid reservoir cap.
Norge GT 8v Braking system Front brake pump FRONT BRAKE LEVER pos. 1 Description Front brake pump U-bolt fixing screw Type M6 Quantity 2 Torque 10 Nm (7.
INDEX OF TOPICS BODYWORK BODYW Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten
Norge GT 8v Bodywork FRONT LIGHTS pos. 1 2 Description Headlamp fixing screw Horn fixing screw pos. 1 Description Instrument panel fixing screw Type M5 M6 Quantity 4 1 Torque 6 Nm (4.42 lbf ft) 10 Nm (7.37 lbf ft) Notes - Torque 3 Nm (2.
Norge GT 8v Bodywork pos. 2 3 Description Ignition lock fixing screw Ignition lock shear head fixing screw pos. 1 2 Description Top fairing fixing screw Top fairing fixing screw Type M8x30 M8x28 Quantity 1 1 Torque 25 Nm (18.44 lbf ft) - Notes At the point of failure Torque 4 Nm (2.95 lbf ft) 4 Nm (2.
Norge GT 8v Bodywork WINDSHIELD pos. 1 2 3 4 5 Description Windshield link rod fixing screw on the frame Aesthetic support fixing screw Engine guide lock to frame upper fixing screw Engine guide lock to frame lower fixing screw Windshield support fixing screw pos. 1 Description Front mudguard fixing screw Type M6x25 M5 M6 M6 M6 Quantity 2 4 2 2 4 Torque 10 Nm (7.37 lbf ft) 4 Nm (2.95 lbf ft) 10 Nm (7.37 lbf ft) 10 Nm (7.37 lbf ft) 10 Nm (7.37 lbf ft) Notes - Torque 4 Nm (2.
Norge GT 8v Bodywork TAIL Tail pos. 1 2 3 Description Handgrip to chassis fixing screw Tail to handgrip and to rear fairings fixing screw Hooks and tail fairing to chassis fixing screw Type M8x25 M5x9 Quantity 5 10 Torque 25 Nm (18.44ft) 4 Nm (2.95 lbf ft) Notes - M8 4 20 Nm (14.
Norge GT 8v Bodywork REAR LIGHTS pos. 1 2 Description Handgrip taillight fixing screw Rear turn indicator fixing screw pos. 1 2 Description Splash guard fixing screw to the chassis ABS support fixing screw to the splash guard 3 Retroreflector support fixing screw to the license plate Retroreflector fixing nut retainer to the support Type M5x16 M6 Quantity 4 2 Torque 4 Nm (2.95 lbf ft) 2 Nm (1.47 lbf ft) Notes - SPLASH GUARD 4 Type M6 SWP M5x20 M5x10 Quantity 6 3 Torque 10 Nm (7.
Norge GT 8v Bodywork • Remove the top fairing glass. Side fairings HEAD GUARD • Undo and remove the three fixing screws. • Remove the head guard. RIGHT SIDE FAIRING • Remove the head guard. • Undo and remove the three screws indicated. • Remove the front fitting of the fairing.
Norge GT 8v • Bodywork Remove the fairing, by pulling it from the centring screw. LEFT SIDE FAIRING • Remove the left fairing lug. • Remove the head guard. • Remove the fairing cover. • Undo and remove the two screws indicated. • Unscrew and remove the lower screw. • Remove the left side fairing.
Norge GT 8v Bodywork Air box • Remove the fuel tank. • Disconnect the connector from the air temperature sensor. • Remove the oil breather pipe. • Unscrew and remove the two screws from the oil vapour recovery reservoir. • Unscrew and remove the tube guide screw on the air filter casing.
Norge GT 8v • Bodywork Move the oil vapour recovery reservoir aside. • Unscrew and remove the two front screws from the air filter casing. • Operating from both sides, loosen the clamp and slide off the sleeve from the throttle body. • Lift the air filter casing and slide off the fuel depression pipe. • Remove the air filter casing.
Norge GT 8v Bodywork Fuel tank • Remove the saddle. • Working from both sides, undo and remove the screw. • Operating from both sides, lift the side fairing to remove it and slide it off the pin. • Working from both sides, undo and remove the front screw. • Undo and remove the rear screw.
Norge GT 8v • Bodywork Lift the fuel tank and remove the pipes from the "T" joint. • Disconnect the connector. • Disconnect the fuel pipe. • Remove the fuel tank by sliding it off and back.
Norge GT 8v Bodywork Instrument cluster cover • Remove the two side covers of the control panel. • Remove the top fairing glass. • Operating from both sides, unscrew the four screws indicated. • Undo and remove the upper front screw. • Lift the control panel together with the instrument panel. • Disconnect the air temperature sensor connector. • Disconnect the connector together with the instrument panel. • Remove the control panel together with the instrument panel.
Norge GT 8v Bodywork Headlight fairing • Remove the left side fairing. • Remove the fuel tank. • Remove the control panel with the instrument panel. • Working from both sides, unscrew and remove the two screws indicated. • If necessary, remove the stud bolts from each side, unscrewing it from the fairing. • Working from both sides, undo and remove the internal screw. • Unscrew and remove the screw below the front headlamp.
Norge GT 8v Bodywork • Disconnect the connectors of the turn indicators. • Disconnect the two connectors from the front headlight. • Remove the upper fairings together with the headlight. See also Side fairings Fuel tank Adjustable windscreen • Remove the upper fairings. • Undo and remove the two lower screws.
Norge GT 8v • Bodywork Undo and remove the two upper screws. • Working from both sides, unscrew and remove the upper windshield fixing screws. • Disconnect the windshield driving engine connector. • Unscrew and remove the two fixing screws and detach the two windshield end of the strokes, leaving them connected to the system. NOTE WHEN REFITTING, FIT THE END OF STROKE DOWNWARDS WITH THE SHORTEST CABLE.
INDEX OF TOPICS PRE-DELIVERY PRE DE Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten
Norge GT 8v Pre-delivery Carry out the listed checks before delivering the motorcycle. WARNING HANDLE FUEL WITH CARE.
Pre-delivery Norge GT 8v - 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.
Norge GT 8v 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 clutc
A ABS: 309, 316 Air filter: 64 Air temperature sensor: 111, 125 Alternator: B Battery: 99, 102 Brake: 323–326, 335 Brake calliper: 323, 324 Brake disc: 324, 325 Brake lever: Brake pads: 325, 326 Brake pump: 335 C Clutch: 122, 175, 178, 179, 216 Coil: 118 Connectors: 127 Crankcase: 49, 215, 222 Crankshaft: 49, 198, 201, 215, 217, 220 Cylinder: 47, 185, 188, 190, 191, 205, 206, 208, 211, 216 D Desmodromic drum: 161 E ECU: 127, 244, 317 Electrical system: 12, 70, 72, 353 Engine oil: 61, 170, 303, 345 Engin
I Identification: 10 Instrument panel: 125 M Maintenance: 8, 59, 322 Maintenance Table: Mudguard: O Oil filter: 63 Oil pressure sensor: 120 Oil sump: 231, 234 P Primary shaft: 155, 160–162 R Radiator: Rear wheel: Recommended products: 50, 281 Run/Stop switch: 126 S Secondary shaft: 157, 160, 162 Shock absorber: Shock absorbers: 271 Side fairings: 342 Side stand: 123 Side stand sensor: 123 Speed sensor: 103 Stand: 123 Start-up: 100 Starter motor: 150, 174 T Tank: 169, 321, 346, 350 Throttle body: Trans
