MOTO GUZZI 1200 SPORT 4V ABS Service Station Manual

SERVICE STATION MANUAL

981103

1200 SPORT 4V ABS

SERVICE STATION

MANUAL

1200 SPORT 4V ABS

THE VALUE OF SERVICE

Only the mechanics of the official Moto Guzzi Service Network know this vehicle well, thanks to constant

technical professional development and Moto Guzzi specific training programmes, and have the tools

needed to carry out maintenance and repair operations correctly.

The reliability of the vehicle also depends on its mechanical conditions. Checking the vehicle before

setting off, carrying out routine maintenance and using only Moto Guzzi Original Spare parts is

fundamental!

For information about the nearest Official Dealer and/or Service Centre, consult the Yellow Pages or

search directly on the inset map in our Official Website:

www.motoguzzi.it

Only by purchasing Moto Guzzi Original Spare Parts will you get a product designed and tested during

the bike designing phase. Moto Guzzi Original Spare Parts are subject to systematic quality control

procedures so that their reliability and performance over time is guaranteed.

The descriptions and illustrations given in this publication are not binding; while the basic features as

described and illustrated in this manual remain unchanged, Moto Guzzi reserves the right, at any time and without being required to update this publication beforehand, to make any changes to components, parts or accessory supplies, which it deems necessary to improve the product or which are required for

manufacturing or commercial reasons.

Not all versions shown in this publication are available in all countries. The availability of individual

versions should be checked with the official Moto Guzzi sales network.

prohibited. Moto Guzzi - After sales service.

The Moto Guzzi brand is owned by Piaggio & C. S.p.A.

SERVICE STATION MANUAL

1200 SPORT 4V ABS

This manual provides the main information to carry out regular maintenance operations on your vehicle. This manual is intended to Moto Guzzi Dealers and their qualified mechanics; several concepts have been deliberately omitted as they are considered unnecessary. As it is not possible to include complete mechanical notions in this manual, users should have basic mechanical knowledge or minimum knowledge about the procedures involved when repairing scooters. Without this knowledge, repairing or checking the vehicle may be inefficient or even dangerous. As the vehicle repair and check procedures are not described in detail, be extremely cautious so as not to damage components or injure individuals. In order to optimise customer satisfaction when using our vehicles, Moto Guzzi s.p.a. commits itself to continually improve its products and the relative documentation. The main technical modifications and changes in repair procedures are communicated to all Moto Guzzi Sales Outlets and its International Subsidiaries. These changes will be introduced in the subsequent editions of the manual. In case of need or further queries on repair and check procedures, consult Moto Guzzi CUSTOMER DEPARTMENT, which will be prepared to provide any information on the subject and any further communications on updates and technical changes related to the vehicle.

NOTE Provides key information to make the procedure easier to understand and carry out.

CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.

WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.

Personal safety Failure to completely observe these instructions will result in serious risk of personal

injury.

Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent damaging the environment.

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee

INDEX OF TOPICS

CHARACTERISTICS CHAR

SPECIAL TOOLS S-TOOLS

MAINTENANCE MAIN

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

ENGINE ENG

POWER SUPPLY P SUPP

SUSPENSIONS SUSP

CHASSIS CHAS

BRAKING SYSTEM BRAK SYS

BODYWORK BODYW

PRE-DELIVERY PRE DE

INDEX OF TOPICS

CHARACTERISTICS CHAR

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 run the engine 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.

Fuel

CAUTION

THE FUEL USED TO POWER INTERNAL COMBUSTION ENGINES IS HIGHLY FLAMMABLE AND MAY BE EXPLOSIVE UNDER CERTAIN CONDITIONS. IT IS THEREFORE RECOMMENDED TO CARRY OUT REFUELLING AND MAINTENANCE PROCEDURES IN A VENTILATED AREA WITH THE ENGINE SWITCHED OFF. DO NOT SMOKE DURING REFUELLING AND NEAR FUEL VAPOURS, AVOIDING ANY CONTACT WITH NAKED FLAMES, SPARKS OR OTHER SOURCES WHICH MAY CAUSE THEM TO IGNITE OR EXPLODE. DO NOT DISPERSE FUEL IN THE ENVIRONMENT. KEEP OUT OF THE REACH OF CHILDREN

Hot components

The engine and the exhaust system components become very hot and remain hot for some time after the engine has been switched off. When handling these components, wear insulating gloves or wait until the engine and the exhaust system have cooled down.

Used engine oil and transmission oil

CAUTION

IT IS ADVISABLE TO WEAR PROTECTIVE IMPERMEABLE GLOVES WHEN SERVICING THE VEHICLE. THE ENGINE OR GEARBOX OIL MAY CAUSE SERIOUS INJURIES TO THE SKIN IF HANDLED FOR PROLONGED PERIODS OF TIME AND ON A REGULAR BASIS. WASH YOUR HANDS CAREFULLY AFTER HANDLING OIL. HAND THE OIL OVER TO OR HAVE IT COLLECTED BY THE NEAREST USED OIL RECYCLING COMPANY OR THE SUPPLIER. DO NOT DISPOSE OF OIL IN THE ENVIRONMENT KEEP OUT OF THE REACH OF CHILDREN

1200 SPORT 4V ABS Characteristics

CHAR - 7

Brake and clutch fluid

BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAINTED SURFACES.

WHEN SERVICING THE BRAKING SYSTEM OR THE CLUTCH SYSTEM, PROTECT THESE COM-

PONENTS 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 ABUNDANT COLD, CLEAN WATER AND SEEK MEDICAL ADVICE.

KEEP OUT OF THE REACH OF CHILDREN

Battery electrolyte and hydrogen gas

CAUTION

THE BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND AS IT CONTAINS SULPHURIC ACID,

IT CAN CAUSE BURNS WHEN IN CONTACT WITH THE SKIN. WHEN HANDLING BATTERY

ELECTROLYTE, WEAR TIGHT-FITTING GLOVES AND PROTECTIVE APPAREL. IN THE EVENT

OF SKIN CONTACT WITH THE ELECTROLYTIC FLUID, RINSE WELL WITH PLENTY OF CLEAN

WATER. IT IS PARTICULARLY IMPORTANT TO PROTECT YOUR EYES BECAUSE EVEN TINY

AMOUNTS OF BATTERY ACID MAY CAUSE BLINDNESS. IF THE FLUID GETS IN CONTACT WITH

YOUR EYES, WASH WITH ABUNDANT WATER FOR FIFTEEN MINUTES AND CONSULT AN EYE

SPECIALIST IMMEDIATELY. THE BATTERY RELEASES EXPLOSIVE GASES; KEEP IT AWAY

FROM FLAMES, SPARKS, CIGARETTES OR ANY OTHER HEAT SOURCES. ENSURE ADE-

QUATE VENTILATION WHEN SERVICING OR RECHARGING THE BATTERY.

KEEP OUT OF THE REACH OF CHILDREN

BATTERY LIQUID IS CORROSIVE. DO NOT POUR IT OR SPILL IT, PARTICULARLY ON PLASTIC

COMPONENTS. ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BAT-

TERY TO BE ACTIVATED.

Maintenance rules

GENERAL PRECAUTIONS AND INFORMATION

When repairing, dismantling and reassembling the vehicle follow the recommendations reported below

carefully.

BEFORE REMOVING COMPONENTS

•

Before dismantling components, remove dirt, mud, dust and foreign bodies from the vehicle. Use the special tools designed for this bike, as required.

COMPONENTS REMOVAL

•

Do not loosen and/or tighten screws and nuts using pliers or any other tools than the specific wrench.

•

Mark the positions on all connection joints (pipes, cables, etc.) before separating them, and identify them with different distinctive symbols.

•

Each component needs to be clearly marked to enable identification during reassembly.

•

Clean and wash the dismantled components carefully using a low-flammability detergent.

•

Keep mated parts together since they have "adjusted" to each other due to normal wear.

Characteristics 1200 SPORT 4V ABS

CHAR - 8

•

Some components must be used together or replaced altogether.

•

Keep away from heat sources.

REASSEMBLY OF COMPONENTS

CAUTION

BEARINGS MUST BE ABLE TO 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.

•

Lubricate parts (whenever possible) before reassembling them.

•

When tightening nuts and screws, start from the ones with the largest section or from the internal ones, moving diagonally. Tighten nuts and screws in successive steps before applying the tightening torque.

•

Always replace self-locking nuts, washers, sealing rings, circlips, O-rings (OR), cotter pins and screws with new ones if their tread is damaged.

•

When assembling the bearings, make sure to lubricate them well.

•

Check that each component is assembled correctly.

•

After a repair or routine maintenance procedure, carry out pre-ride checks and test the vehicle on private grounds or in an area with low traffic density.

•

Clean all coupling surfaces, oil guard rims and gaskets before refitting them. Smear a light layer of lithium-based grease on the oil guard rims. Reassemble oil guards and bearings with the brand or lot number facing outward (visible side).

ELECTRIC CONNECTORS

Electric connectors must be disconnected as described below; failure to comply with this procedure causes irreparable damage to both the connector and the cable harness: Press the relevant safety hooks, if any.

•

Grip the two connectors and disconnect them by pulling them in opposite directions.

•

If any signs of dirt, rust, moisture, etc. are noted, clean the inside of the connector carefully with a jet of compressed air.

•

Ensure that the cables are correctly fastened to the internal connector terminals.

•

Then connect the two connectors, ensuring that they couple correctly (if fitted with clips, you will hear them "click" into place).

CAUTION

TO DISCONNECT THE TWO CONNECTORS, DO NOT PULL THE CABLES.

NOTE

THE TWO CONNECTORS CONNECT ONLY FROM ONE SIDE: CONNECT THEM THE RIGHT WAY ROUND.

TIGHTENING TORQUES

CAUTION

DO NOT FORGET THAT THE TIGHTENING TORQUES OF ALL FASTENING ELEMENTS ON WHEELS, BRAKES, WHEEL BOLTS AND ANY OTHER SUSPENSION COMPONENTS PLAY A KEY ROLE IN ENSURING VEHICLE SAFETY AND MUST COMPLY WITH SPECIFIED VALUES.

1200 SPORT 4V ABS Characteristics

CHAR - 9

CHECK THE TIGHTENING TORQUES OF FASTENING PARTS ON A REGULAR BASIS AND AL-

WAYS USE A TORQUE WRENCH TO REASSEMBLE THESE COMPONENTS. FAILURE TO COM-

PLY WITH THESE RECOMMENDATIONS MAY CAUSE ONE OF THESE COMPONENTS TO GET

LOOSE AND EVEN DETACHED, THUS BLOCKING A WHEEL, OR OTHERWISE COMPROMISE

VEHICLE HANDLING. THIS CAN LEAD TO FALLS, WITH THE RISK OF SERIOUS INJURY OR

DEATH.

Running-in

Engine run-in is essential to ensure engine long life and correct operation. Twisty roads and gradients

are ideal to run in engine, brakes and suspensions effectively. Vary your riding speed during the run-

in. This ensures that components operate under both "loaded" and "unloaded" conditions, allowing the

engine components to cool.

CAUTION

THE CLUTCH MAY EMIT A SLIGHT BURNING SMELL WHEN FIRST USED. THIS PHENOMENON

SHOULD BE CONSIDERED NORMAL AND WILL DISAPPEAR AS SOON AS THE CLUTCH

PLATES GET ADAPTED.

IT IS IMPORTANT TO STRAIN ENGINE COMPONENTS DURING RUN-IN, HOWEVER, MAKE SURE

NOT TO OVERDO THIS.

CAUTION

THE FULL PERFORMANCE OF THE VEHICLE IS ONLY AVAILABLE AFTER THE SERVICE AT

THE END OF THE RUNNING IN PERIOD.

Follow these guidelines:

•

Do not twist the throttle grip abruptly and completely when the engine is working at a low revs, either during or after run-in.

•

During the first 100 Km (62 miles) use the brakes gently, avoiding sudden or prolonged braking. That is to permit the adequate adjustment of the pad friction material to the brake discs.

AFTER THE SPECIFIED MILEAGE, TAKE THE VEHICLE TO AN OFFICIAL Moto Guzzi DEALER

FOR THE CHECKS INDICATED IN THE "AFTER RUN-IN" TABLE IN THE SCHEDULED MAINTE-

NANCE SECTION TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHI-

CLE.

Vehicle identification

SERIAL NUMBER LOCATION

These numbers are necessary for vehicle registration.

NOTE

ALTERING IDENTIFICATION NUMBERS MAY BE SERIOUSLY PUNISHABLE BY LAW. IN PAR-

TICULAR, MODIFYING THE FRAME NUMBER IMMEDIATELY VOIDS THE WARRANTY.

Characteristics 1200 SPORT 4V ABS

CHAR - 10

This number consists of numbers and letters, as in the example shown below.

ZGULPR010YMXXXXXX KEY: ZGU: WMI (World manufacturer identifier) code; LP: model; R01: version variation; 0: digit free Y year of manufacture M: production plant (M= Mandello del Lario); XXXXXX: progressive number (6 digits); CHASSIS NUMBER

The chassis number is stamped on the right side of the headstock.

ENGINE NUMBER

The engine number is stamped on the left side, close to the engine oil level check cap.

Dimensions and mass

WEIGHT AND DIMENSIONS

Specification

Desc./Quantity

Length 2195 mm (86.4 in)

Width 870 mm (34.2 in)

Height (at windshield) 1160 mm (45.67 in)

Saddle height 800 mm (31.5 in)

Minimum earth clearance 185 mm (7.3 in)

Wheelbase 1495 mm (58.8 in)

Kerb weight 257 kg (567 lb)

Engine

ENGINE

Specification

Desc./Quantity

Type traverse-mounted twin-cylinder four-stroke V 90°

Cylinder number 2

Cylinder arrangement V 90°

Bore / stroke 95 x 81.2 mm (3.74 x 3.20 in)

Engine capacity 1151 cm³ (70 cu.in)

1200 SPORT 4V ABS Characteristics

CHAR - 11

Specification Desc./Quantity

Compression ratio 11 : 1

Electric starter

Engine idle speed 1100 ± 100 rpm

Clutch hydraulically controlled single-plate dry clutch with incorpora-

ted flexible coupling

Lubrication system Pressure-fed, controlled by valves and trochoidal pump

Air filter cartridge-type dry filter Cooling air and oil cooled with independent trochoidal pump and oil

pressure control valve

Timing system diagram single overhead camshaft with bucket tappets and rocker-op-

erated valves

Values valid with control clearance between rocker and valve intake: 0.15 mm (0.0059 in)

outlet: 0.20 mm (0.0079 in)

Transmission

TRANSMISSION

Specification Desc./Quantity

Primary drive with gears, ratio: 24/35 = 1:1.4583

Gearbox Mechanical, 6 speeds with foot lever on the left hand side of

the engine

Gear ratios, 1st gear 17/38 = 1:2.2353

Gear ratios, 2nd gear 20/34 = 1:1.7

Gear ratios, 3rd gear 23/31 = 1:1.3478 Gear ratios, 4th gear 26/29 = 1:1.1154 Gear ratios, 5th gear 31/29 = 1:0.9355 Gear ratios, 6th gear 30/24 = 1:0.8

Final drive with U-joint

Ratio 12/44 = 1:3.6667

Capacities

CAPACITY

Specification

Desc./Quantity

Engine oil Oil change and oil filter replacement: 3,500 cm³ (214 cu.in)

Gearbox oil 500 cm³ (30.5 cu.in)

Transmission oil 380 cm³ (23.2 cu.in)

Fork oil quantity (for each stem): 480 cm³ (29.29 cu.in)

Fuel (reserve included) 23 l (6.1 gal)

Fuel reserve 4 l (1.06 gal)

Seats 2

Vehicle maximum load 221 kg (487 lb) (rider + passenger + luggage)

Electrical system

ELECTRICAL SYSTEM

Specification

Desc./Quantity

Spark plug NGK PMR8B (long life)

Alternatively:

Spark plug NGK CR8EKB (long life)

Electrode gap 0.6 - 0.7 mm (0.024 - 0.028 in)

Battery 12 V - 18 Ampere/hour

Generator with permanent magnet, 12 V - 550 W

Main fuses 30 A

ABS version fuses 40A - 25A

ABS version auxiliary fuses 3A - 15A - 20A - 10A

Tail light 12V - 5 W

Low-beam light 12 V - 55 W H7

Characteristics 1200 SPORT 4V ABS

CHAR - 12

Specification Desc./Quantity

High-beam light 12 V - 65 W H9

Turn indicators 12V - 10 W (orange bulb)

Rear daylight running light/stop light LED

Dashboard lighting LED

License plate light 12V - 5 W

Turn indicator warning light LED

ABS Warning Light LED

Neutral gear warning light LED

Alarm warning light LED

Side stand down warning light LED

Low fuel warning light LED

High beam warning light LED

Antitheft device warning light LED

Gear shift warning light LED

Frame and suspensions

CHASSIS AND SUSPENSIONS

Specification Desc./Quantity

Type high strength steel tube chassis

Trail 120 mm (4.72 in)

Front suspension hydraulic telescopic fork, Ø 45 mm (1.77 in) stems, adjustable

at spring preloading.

Headstock angle 25° 30'

Wheel travel 120 mm (4.72 in)

Rear single arm suspension with progressive linkage, single shock

absorber with adjustable rebound and ergonomic knob for

spring preloading adjustment.

Wheel travel 140 mm (5.5 in)

SIZES A AND B

Specification

Desc./Quantity

Size A 793.4 mm (31.24 in) Size B 344.5 mm (13.56 in)

Brakes

BRAKES

Specification

Desc./Quantity

Front twin Ø 320 mm (12.6 in) stainless steel floating disc, calliper

with 4 different and counteracting plungers

Rear 282 mm (11.1 in) diam. stainless steel disc

1200 SPORT 4V ABS Characteristics

CHAR - 13

Wheels and tyres

WHEELS AND TYRES

Specification Desc./Quantity

Type hollow 3-spoke rim in chilled cast aluminium alloy Front wheel rim 3.50" x 17" Rear wheel rim 5.50" x 17"

Tyres METZELER Roadtec Z6

METZELER Sportec M5

MICHELIN Pilot Road

DUNLOP D220 ST Sportmax

DUNLOP Qualifier

Tyres - front size 120/70 - ZR 17''

Inflation pressure (front) 2.5 bar (250 kPa) (36.3 PSI)

Inflation pressure with passenger (front) 2.5 bar (250 kPa) (36.3 PSI)

Tyres - Rear size 180 / 55 - ZR 17''

Inflation pressure (rear) 2.8 bar (280 kPa) (40.6 PSI)

Inflation pressure with passenger (rear) 2.8 bar (280 kPa) (40.6 PSI)

Supply

FUEL SYSTEM

Specification

Desc./Quantity

Fuel system Electronic injection (Weber . Marelli) with Stepper motor

Venturi diameter: 50 mm (1.97 in)

Fuel Premium unleaded petrol, minimum octane rating 95 (NORM)

and 85 (NOMM)

Tightening Torques

HEADS

Name

Torque in Nm

Oil cap (2) 25 Nm (18.44 lb ft)

Rocking lever support nut - M10x1.5 (8) 15 Nm (11.06 lb ft) + 42 Nm (30.98 lb ft)

Camshaft - rocking levers support fixing screws (12) 17 Nm (12.54 lb ft)

Head fixing screw (4) - pre-tightening 15 Nm (11.06 lb ft)

Head fixing screw (4) - final tightening 42 Nm (31 lb ft)

Screw fixing head to chain compartment - M6x120 (4) 10 Nm (7.38 lb ft)

Oil temperature sensor 11 Nm (8.11 lb ft) - Loctite 243

Oil temperature sensor container 11 Nm (8.11 lb ft) - Loctite 601

Head covers fixing screws (8) 8 Nm (5.9 lb ft)

Spark plug (2) 15 Nm (11.06 lb ft) - Molykote

CRANKCASE

Name

Torque in Nm

Crankcase stud bolt - cylinder (8) 25 Nm (18.44 lb ft) Transmission side flange stud bolt - M8x66 (3) 35 Nm (25.81 lb ft) Transmission side flange stud bolt - M8x75 (2) 35 Nm (25.81 lb ft)

Gear side crankshaft flange screw - TE M8x25 (8) 26 Nm (19.18 lb ft)

Timing system cover screw - TCEI M8x55 (4) 25 Nm (18.44 lb ft)

Timing system cover screw - TCEI M6x30 (10) 10 Nm (7.38 lb ft)

Oil vapour union screw - TCEI M6x20 (2) 10 Nm (7.38 lb ft)

TCEI M6x40 Screw (2) 10 Nm (7.38 lb ft)

Timing sensor - TCEI M5x12 (2) 6 Nm (4.42 lb ft)

Service shaft bearing locking screw (2) 10 Nm (7.38 lb ft)

Oil pressure sensor (1) 25 Nm (18.44 lb ft)

Screw fixing oil pressure sensor support - TCEI M10x20 (1) 18 Nm (13.28 lb ft)

Oil cap (2) 25 Nm (18.44 lb ft)

Characteristics 1200 SPORT 4V ABS

CHAR - 14

OIL SUMP

Name Torque in Nm

Oil pipe on sump reduction (1) 20 Nm (14.75 lb ft)

Oil pipe on sump 20 Nm (14.75 lb ft)

Oil sump lower screw - TCEI M6x30 (4) 10 Nm (7.38 lb ft)

Oil sump screw - TCEI M6x55 (14) 10 Nm (7.38 lb ft)

Oil sump screw - TCEI M6x60 (2) 10 Nm (7.38 lb ft)

Oil drainage plug - M10x1 (1) 20 Nm (14.75 lb ft)

Oil filter (1) 15 Nm (11.06 lb ft)

Oil filter fitting (1) 40 Nm (29.5 lb ft) - Loctite 243

Oil pipe in sump 20 Nm (14.75 lb ft) - Loctite 648

Pressure-relief plug 40 Nm (29.5 lb ft)

Cap on oil sump flange (2) 20 Nm (14.75 lb ft)

Cap (1) 40 Nm (29.5 lb ft)

CRANKSHAFT - FLYWHEEL

Name Torque in Nm

Connecting rod screw (4) - pre-tightening 40 Nm (29.5 lb ft)

Connecting rod screw (4) - final tightening 80 Nm (59 lb ft)

Screw fixing clutch plate on crankshaft - M8x25 (6) 42 Nm (30.98 lb ft) - Loctite 243

Screw fixing clutch bell on disc - M7x16 (6) 20 Nm (14.75 lb ft)

Start-up crown gear fixing screw (6) 10 Nm (7.38 lb ft)

OIL PUMP

Name

Torque in Nm

Oil pump fixing screws - M6x45 (3) 10 Nm (7.38 lb ft)

Oil pump gear nut - M10x1.25 (1) 20 Nm (14.75 lb ft)

Pressure-relief plug 40 Nm (29.5 lb ft)

Cooling oil intake filter fixing screw (5) 10 Nm (7.38 lb ft)

Lubrication oil intake filter fixing screw (2) 10 Nm (7.38 lb ft)

TIMING SYSTEM

Name

Torque in Nm

Service shaft flange screw - TBEI M6x14 (2) 8 Nm (5.9 lb ft)

Timing system gear nut on service shaft - M18 (1) 150 Nm (110.6 lb ft)

Timing system gear nut on crankshaft - M25 (1) 200 Nm (147.51 lb ft)

Belt tension 50 Nm (36.88 lb ft)

Timing system upper gear TE screw (2) 30 Nm (22.13 lb ft)

Screw fixing timing system upper gear closing cap - TBEI

M5x10 (4)

7 Nm (5.16 lb ft)

Cylinder chain tensioner cap (2) 30 Nm (22.13 lb ft)

Screw fixing movable chain slider (2) 25 Nm (18.44 lb ft)

Timing system outer cover screw - TCEI M6x16 (5) 10 Nm (7.38 lb ft)

ALTERNATOR

Name

Torque in Nm

Alternator fixing screw - TCEI M8x45 (1) 22 Nm (16.23 lb ft)

Alternator fixing nut - M10x1.5 (1) 30 Nm (22.13 lb ft)

Alternator pulley nut on crankshaft - M16 (1) 80 Nm (59 lb ft) - Loctite 243

GEARBOX

Name

Torque in Nm

Gear shift cable lever nut 10 Nm (7.38 lb ft)

Gear shift tie rod lever nut on gear pre-selector 10 Nm (7.38 lb ft)

Gearbox to crankcase fixing nut - M8 (5) 20 Nm (14.75 lb ft)

TE flanged screw fixing gearbox to crankcase - M8x45 (1) 20 Nm (14.75 lb ft)

Oil cap M18x1.5 (1) 28 Nm (20.65 lb ft)

Breather cap (1) 8 Nm (5.9 lb ft)

Gear in neutral sensor (1) 10 Nm (7.38 lb ft)

Oil drainage plug - M10x1 (1) 24 Nm (17.7 lb ft)

Transmission shaft ring nut (1) 100 Nm (73.76 lb ft)

1200 SPORT 4V ABS Characteristics

CHAR - 15

CHASSIS TO ENGINE UNIT

Name Torque in Nm

M6x40 TCEI DA screw 8 -12 Nm

Reduction 20 Nm

FUEL SUPPLY CONTROL UNIT

Name Torque in Nm

M5x12 TCEI screw 6 -7 Nm

Stainless M5x16 TBEI flanged screw 6 -7 Nm

M6x25 TCEI DA screw 8 -12 Nm

FRAME

Name Torque in Nm

Electronic control unit retainer + coil plates 10 Nm

Electronic control unit retainer 10 Nm

Tank support rubber rings to chassis retainer 25 Nm

Gearbox to chassis retainer 80 Nm

Coil retainer 2 Nm

Engine retainer 80 Nm

Left and right footrest plate to chassis upper retainer 20 Nm

Right footrest plate to chassis lower retainer 30 Nm

Left footrest plate to chassis lower retainer 30 Nm

Right/left protection cover retainer 6 Nm

Plate ring to plate retainer 6 Nm

Handgrip to chassis fixing screw 25 Nm

Cover to handgrip retainer 25 Nm

FOOTRESTS AND LEVERS

Name

Torque in Nm

Footrest rubber retainer 10 Nm

Rod retainer (nut) 10 Nm

Gear shift lever / brake pin retainer 10 Nm

Gear shift lever / pre-selector retainer 10 Nm

Spring hook pin 4 Nm

SIDE STAND

Name

Torque in Nm

Stand plate to engine retainer 80 Nm

Side stand retainer pin 10 Nm

Switch fixing screw 10 Nm

Lock nut 30 Nm

M10x1.25 low nut 30 Nm (22.12 lb ft) - Loctite 243

CENTRE STAND

Name

Torque in Nm

Stand to plates fixing screw 50 Nm

Pipe guide ring to plates fixing screw 10 Nm

SWING ARM

Name

Torque in Nm

Swingarm on bushing clamp retainer 10 Nm Swingarm on bevel gear pair retainer 50 Nm

Reaction rod to bevel gear pair retainer 50 Nm

Reaction rod to chassis retainer 50 Nm

Swingarm bolt to swingarm retainer 60 Nm

Preloading bushing to swingarm bolt retainer 10 Nm

FRONT SUSPENSION

Name

Torque in Nm

Speed sensor retainer 10 Nm

Characteristics 1200 SPORT 4V ABS

CHAR - 16

Name Torque in Nm

Tube lock plate to steering base retainer 6 Nm Stanchion to lower / upper plate retainer 25 Nm

Headstock ring nut 40 Nm

Headstock counter ring nut manual + 90 degrees

Upper yoke fixing cap 100 Nm

Fork hubs closing 10 Nm

REAR SUSPENSION

Name Torque in Nm

Shock absorber to chassis retainer - 8.8 50 Nm

Double connecting rod/shock absorber retainer - 10.9 40 Nm

Single connecting rod/double connecting rod retainer - 10.9 50 Nm

Single connecting rod to chassis retainer - 8.8 50 Nm

Double connecting rod/swingarm retainer - 10.9 50 Nm

AIR FILTER BOX

Name Torque in Nm

Filter box cover/filter box bracket 3 Nm

Blow by tank to filter box cover retainer 3 Nm

Air temperature sensor retainer 2 Nm

EXHAUST

Name Torque in Nm

Exhaust pipe to engine retainer 25 Nm

Exhaust pipe to compensator retainer (clamp) 10 Nm

Compensator to silencer retainer (clamp) 10 Nm

Lambda probe retainer 38 Nm

Silencer to support retainer (screw +nut) 25 Nm

FRONT WHEEL

Name

Torque in Nm

Wheel axle nut 80 Nm

Disc retainer 30 Nm

REAR WHEEL

Name

Torque in Nm

Disc retainer 30 Nm

Rear wheel retainer 10.9 110 Nm

FRONT BRAKING SYSTEM

Name

Torque in Nm

Front brake right and left calliper retainer 40 Nm

REAR BRAKING SYSTEM

Name

Torque in Nm

Rear brake calliper retainer 50 Nm

Rear brake lever pin 15 Nm

Rear brake fluid reservoir retainer 3 Nm

Rear brake fluid reservoir support to plate retainer 10 Nm

Rear brake rod lock nut manual

Brake lever spring to plate retainer 6 Nm

Brake pump retainer 10 Nm

HANDLEBAR AND CONTROLS

Name

Torque in Nm

Lower U-bolt fixing screws - M8x35 (4) 25 Nm Lower U-bolt fixing screws - M8x25 (2) 25 Nm Upper U-bolt fixing screws - M8x35 (4) 25 Nm

Anti-vibration counterweight fastener 10 Nm

1200 SPORT 4V ABS Characteristics

CHAR - 17

ELECTRICAL SYSTEM

Name Torque in Nm

Horn retainer 15 Nm

Speed sensor to front fork retainer 12 Nm

INSTRUMENT PANEL AND LIGHTS

Name Torque in Nm

Instrument panel support to light support retainer 10 Nm

Instrument panel support to fork upper plate retainer 25 Nm

Instrument panel retainer 3 Nm

Light support to fork lower plate retainer 25 Nm

Light + turn indicators retainer 10 Nm

Taillight to handgrip retainer 4 Nm

FUEL PUMP FLANGE

Name Torque in Nm

Tank breather joint 6 Nm

Pump support to tank retainer 4 Nm

FUEL TANK

Name Torque in Nm

Filler to tank retainer 4 Nm

Rear screw fixing the tank to the chassis - M8x45 25 Nm

CHASSIS / FAIRINGS (FRONT)

Name

Torque in Nm

Air inlet to tank retainer 4 Nm

Lug to engine retainer 25 Nm

Right to left lug retainer 4 Nm

Front mudguard retainer 4 Nm

Windshield internal fixing screw 35 Nm

CHASSIS/ FAIRINGS (REAR)

Name

Torque in Nm

Tail section + fairing retainer 4 Nm

Tail section to handgrip retainer 4 Nm

Net hooks to chassis retainer 25 Nm

Retroreflector to support retainer 4 Nm

Retroreflector support to license plate holder retainer 4 Nm

License plate lamp to license plate holder retainer 4 Nm

(M6) Passenger seat cover / saddle fixing screw 55 Nm

ABS support to splash guard retainer 3 Nm

FINISHINGS

Name

Torque in Nm

Ignition lock retainer - shear head screw - Nm

Ignition lock retainer 25 Nm

Overhaul data

Assembly clearances

Cylinder - piston assy.

Measurement of the cylinder diameter must be done at three heights, turning the dial gauge 90°. Check that cylinders and pistons are of the same selection types (D, E, F).

Characteristics 1200 SPORT 4V ABS

CHAR - 18

Check clearance between cylinders and pistons on the selected diameter; if it exceeds the value specified, it is necessary to replace cylinders and pistons. The pistons of an engine must be balanced; a weight difference of up to 1.5 g (0.0033 lb) is allowed.

PISTON - CYLINDER SELECTION TYPES

Specification Desc./Quantity

Piston diameter - selection D 94.935 - 94.945 mm (3.73759 - 3.73798 in)

Cylinder diameter - selection D 95.000 - 95.010 mm (3.74015 - 3.74054 in)

Piston diameter - selection E 94.945 - 94.955 mm (3.73798 - 3.73837 in)

Cylinder diameter - selection E 95.010 - 95.020 mm (3.74054 - 3.74093 in)

Piston diameter - selection F 94.955 - 94.965 mm (3.73837 - 3.73877 in)

Cylinder diameter - selection F 95.020 - 95.030 mm (3.74093 - 3.74133 in)

PIN - PISTON COUPLING

Specification

Desc./Quantity

Pin diameter 21.998 - 21.994 mm (0.86606 - 0.86590 in)

Pin hole diameter on piston 22.016 - 22.011 mm (0.86677 - 0.86657 in)

Clearance between pin and holes on piston 0.013 - 0.022 mm (0.00051 - 0.00087 in)

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.

1200 SPORT 4V ABS Characteristics

CHAR - 19

CLEARANCE BETWEEN PISTON RINGS AND SEATS ON PISTON

Specification Desc./Quantity

Top ring 0.030 - 0.065 mm (0.00118 - 0.00256 in)

Middle ring 0.020 - 0.055 mm (0.00079 - 0.00216 in)

Oil scraper ring 0.010 - 0.045 mm (0.00039 - 0.00177 in)

Gap between the end of the piston rings inserted in the cylinder:

•

Top and middle piston ring: 0.40 - 0.65 mm (0.00158 - 0.00255 in)

•

Oil scraper piston ring: 0.30 - 0.60 mm (0.00118 - 0.00236 in).

Crankcase - crankshaft - connecting rod

CRANKSHAFT SEAT (TIMING SYSTEM SIDE)

Specification Desc./Quantity

Diameter of crankshaft main journal, timing system side 37.975 - 37.959 mm (1.49507 - 1.49444 in)

Inside diameter of crankshaft bushing, timing system side 38.016 - 38.0 mm (1.49669 - 1.49606 in)

Clearance between bushing and main journal (timing system

side)

0.025 - 0.057 mm (0.00098 - 0.00224 in)

CRANKSHAFT SEAT ( CLUTCH SIDE)

Specification

Desc./Quantity

Diameter of crankshaft main journal, clutch side 53.97 - 53.961 mm (2.12480 - 2.12444 in)

Inside diameter of crankshaft bushing on clutch-side flange 54.019 - 54.0 mm (2.12673 - 2.12598 in)

Clearance between bushing and main journal (clutch side) 0.030 - 0.058 mm (0.00118 - 0.00228 in)

Slot packing system

•

Fit both pistons on the connecting rods.

•

Working from both sides, fit the gasket between the crankcase and the cylinder on the crankcase.

•

Fit both cylinders.

•

Take the left cylinder piston to TDC and lock crankshaft rotation.

Specific tooling

020675Y Service shaft gear lock

•

Thoroughly clean the upper surface of both cylinders.

•

Place the tool on the left cylinder to determine the "squish" (X).

•

Fasten the tool with the nuts of the stud bolts.

Specific tooling

Characteristics 1200 SPORT 4V ABS

CHAR - 20

020676Y Dial gauge support for piston position checking

•

Reset the micrometer on the cylinder rim.

•

Move the tool so that the micrometer feeler reaches the top point of the piston crown.

•

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.

•

Place the tool on the right cylinder stud bolts to determine the "squish" (X).

Specific tooling

020676Y Dial gauge support for piston position checking

•

Repeat the same operations to determine the thickness of the left cylinder gasket between cylinder and head also for the right cylinder.

CYLINDER GASKET THICKNESS - HEAD

Specification

Desc./Quantity

Value (X) -0.56 / -0.37 mm (-0.022 / -0.0146 in) gasket thickness: 0.65 mm (0.0256 in)

Value (X) -0.37 / -0.19 mm (-0.0146 / -0.0075 in) gasket thickness: 0.85 mm (0.0335 in)

Value (X) -0.19 / 0 mm (-0.0075 / 0 in) gasket thickness: 1.05 mm (0.0413 in)

MOTO GUZZI 1200 SPORT 4V ABS Service Station Manual

Specifications and Main Features

Frequently Asked Questions

User Manual