MOTO GUZZI Griso V1100 Workshop Manual
workshopmanual
00/2005-11
UK
Cod.
UK
Cod. 8140904
1288 5
INTRODUCTION
0 - 1
Griso V1100
INTRODUCTION 0
INTRODUCTION
0 - 2
Griso V1100
SUMMARY
0.1. INTRODUCTION .............................................................................................................................................. 3
0.1.1. FOREWORD ............................................................................................................................................. 3
0.1.2. REFERENCE MANUALS .......................................................................................................................... 4
0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS ........................................................................................ 5
INTRODUCTION
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Griso V1100
0.1. INTRODUCTION
0.1.1. FOREWORD
This manual provides the information required for normal servicing.
This publication is intended for use by Moto Guzzi Dealers and their qualified mechanics; many concepts have been
omitted on purpose as their inclusion would be superfluous. Since complete mechanical explanations have not been
included in this manual, the reader must be familiar with basic notions of mechanics, as well as with basic repair
procedures. Without such familiarity, repairs and checks could be ineffective and even hazardous. Since the repair and
vehicle check instructions are not exhaustive, special care must be taken to avoid damage and injury. Moto Guzzi s.p.a.
undertakes to constantly improve the design of its products and their literature to ensure that the customer is satisfied of
the product. The main technical modifications and changes in repair procedures are communicated to all Moto Guzzi
dealers and agencies world-wide. Such modifications will be entered in subsequent editions of the manual. Should you
need assistance or clarifications about the inspection and repair procedures, please contact the Moto Guzzi SERVICE
DEPT., they will be glad to give you any information on the matter, or supply you with any detail on updates and technical
changes applied to the vehicle.
Moto Guzzi s.p.a. reserves the right to make changes to its products at any time, barring any such changes as may alter
the essential features of a product as specified in the relevant manual.
All rights of storage using electronic means, reproduction and total or partial adaptation, whatever the means adopted,
are reserved in all countries.
Third parties' products are only mentioned for information purposes, and constitute no engagement.
Moto Guzzi s.p.a. is not liable in any way for the performance or use of these products.
For further details, see (REFERENCE MANUALS).
First edition: November 2005
Produced and printed by:
VALLEY FORGE DECA
Ravenna, Modena, Torino
DECA s.r.l.
Legal and Administrative headquarters
Via Vincenzo Giardini, 11
48022 Lugo (RA) - Italy Tel. 0545 - -216611
Fax 0545 - -216610
E-mail: deca@vftis.spx.com
www.vftis.com
DECA s.r.l.
via Vincenzo Giardini, 11 - 48022 Lugo (RA) - Italy
Tel. +39 - 0545 216611
Fax +39 - 0545 216610
E-mail: deca@vftis.spx.com
www.vftis.com
On behalf of:
Moto Guzzi s.p.a.
via E.V. Parodi, 57- 23826 Mandello del Lario (Lecco) - Italy
Tel. +39 – 0341 - 709111
Fax +39 – 0341 - 709220
www.motoguzzi.it
www.servicemotoguzzi.com
INTRODUCTION
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Griso V1100
0.1.2. REFERENCE MANUALS
PARTS CATALOGUES
guzzi part# (description)
GU078_00
OWNER'S MANUALS
guzzi part# (description)
06.90.00.00
06.90.00.01
CHASSIS WORKSHOP MANUAL
guzzi part# (description)
8140900
8140901
8140902
8140903
8140904
8140905
8CM0095
8CM0096
ENGINE WORKSHOP MANUAL
guzzi part# (description)
8CM0093
8CM0094
INTRODUCTION
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Griso V1100
0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS
# = number
< = less than
> = greater than
≤ = less than or equal to
≥ = greater than or equal to
~ = approximately
∞ = infinity
°C = degrees Celsius (centigrade)
°F = degrees Fahrenheit
± = plus or minus
A.C. = alternating current
A = Ampere
Ah = Ampere per hour
API = American Petroleum Institute
AT = high voltage
AV/DC = Anti-Vibration Double Countershaft
bar = pressure measurement (1 bar = 100 kPa)
D.C. = direct current
cc = cubic centimetres
CO = carbon monoxide
CPU = Central Processing Unit
DIN = German industrial standards (Deutsche Industrie Norm)
DOHC = Double Overhead Camshaft
ECU = Electronic Control Unit
rpm = revolutions per minute
HC = unburnt hydrocarbons
ISC = Idle Speed Control
ISO = International Standardization Organization
kg = kilograms
kgm = kilogram metre (1 kgm = 10 Nm)
km = kilometres
km/h = kilometres per hour
kΩ = kilo Ohm
kPa = kiloPascal (1 kPa = 0.01 bar)
KS = clutch side (from the German "Kupplungsseite")
kW = kilowatt
l = litres
LAP = racetrack lap
LED = Light Emitting Diode
LEFT SIDE = left-hand side
m/s = metres per second
max = maximum
mbar = millibar (1 mbar = 0.1 kPa)
mi = miles
MIN = minimum
MPH = miles per hour
MS = flywheel side (from the German "Magnetoseite")
MΩ = MegaOhm
N.A. = Not Available
N.O.M.M. = Motor Octane Number
N.O.R.M. = Research Octane Number
Nm = Newton metre (1 Nm = 0.1 kgm)
Ω = ohm
PICK-UP = pick-up
BDC = Bottom Dead Centre
TDC = Top Dead Centre
PPC = Pneumatic Power Clutch
RIGHT SIDE = right-hand side
SAE = Society of Automotive Engineers
SAS = Secondary Air System
INTRODUCTION
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Griso V1100
TEST = diagnostic check
T.B.E.I. = crown-head Allen screw
T.C.E.I. = cheese-head Allen screw
T.E. = hexagonal head
T.P. = flat head screw
TSI = Twin Spark Ignition
UPSIDEDOWN = inverted fork
V = Volt
W = Watt
Ø = diameter
GENERAL INFORMATION
1 - 1
Griso V1100
GENERAL INFORMATION 1
GENERAL INFORMATION
1 - 2
Griso V1100
SUMMARY
1.1 STRUCTURE OF THE MANUAL...................................................................................................................... 3
1.1.1 CONVENTIONS USED IN THE MANUAL................................................................................................. 3
1.1.2 SAFETY WARNINGS ................................................................................................................................ 4
1.2 GENERAL RULES............................................................................................................................................ 5
1.2.1 BASIC SAFETY RULES............................................................................................................................ 5
1.3 DANGEROUS ELEMENTS............................................................................................................................... 8
1.3.1 WARNINGS............................................................................................................................................... 8
1.4 RUNNING-IN .................................................................................................................................................. 11
1.4.1 RUNNING-IN ........................................................................................................................................... 11
1.5 POSITION OF THE SERIAL NUMBERS ........................................................................................................ 12
1.5.1 POSITION OF THE SERIAL NUMBERS................................................................................................. 12
GENERAL INFORMATION
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Griso V1100
1.1 STRUCTURE OF THE MANUAL
1.1.1 CONVENTIONS USED IN THE MANUAL
• This manual is divided in sections and subsections, each covering a set of the most significant components. For
quick reference, see the summary of sections.
• Unless expressly specified otherwise, assemblies are reassembled by reversing the assembly procedure.
• The terms "left" and "right" are referred to the motorcycle when viewed from the riding position.
• Motorcycle operation and basic maintenance are covered in the "OWNER'S MANUAL".
In this manual any variants are identified with these symbols:
optional
catalytic version
- all versions
MP national certification
SF European certification (EURO 1 limits)
VERSION:
Italy
Greece
Malaysia
United
Kingdom
Holland
Chile
Austria
Switzerland
Croatia
Portugal
Denmark
Australia
Finland
Japan
United States of America
Belgium
Singapore
Brazil
Germany
Slovenia
South Africa
France
Israel
New Zealand
Spain
South Korea
Canada
GENERAL INFORMATION
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Griso V1100
1.1.2 SAFETY WARNINGS
The symbols and warnings used throughout this manual have the following meanings:
Safety warning. When you find this symbol on the vehicle or in the manual, be careful of the potential
risk of personal injury. Disregarding the instructions identified by this symbol may compromise the
safety of the user, the motorcycle and third parties.
DANGER
Indicates a potential hazard which may result in serious injury or even death.
WARNING
Indicates a potential hazard which may result in minor personal injury or damage to the vehicle.
NOTE The word "NOTE" in this manual identifies important information or instructions.
GENERAL INFORMATION
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Griso V1100
1.2 GENERAL RULES
1.2.1 BASIC SAFETY RULES
CARBON MONOXIDE
When an operation must be performed with the engine running, position the motorcycle outdoors in a well-ventilated
area.
Never run the engine in an enclosed place.
Use an exhaust emission extraction system when working indoors.
DANGER
Exhaust gases contain carbon monoxide, a poisonous gas which, if inhaled, may cause loss of
consciousness or even death.
FUEL
DANGER
The fuel used to operate engines is highly flammable and becomes explosive under particular
conditions.
Refuelling and maintenance operations should be carried out in a well-ventilated area, with the engine
off.
Do not smoke when refuelling or in the proximity of sources of fuel vapours. Avoid contact with bare
flames, sources of sparks and any other source which may ignite fuel or lead to explosion.
DO NOT DISPOSE OF FUEL IN THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
HOT COMPONENT PARTS
The engine and exhaust component parts become hot when the engine is running and will stay hot for some time after
the engine has been stopped.
Wear insulating gloves before handling these components or allow for the engine and the exhaust system to cool down
before proceeding.
USED GEARBOX AND FORK FLUIDS
DANGER
Wear latex gloves when servicing.
Prolonged or repeated contact with gear fluid may cause severe skin damage.
Wash your hands thoroughly after handling.
Dispose of it through the nearest waste oil reclamation firm or through the supplier.
Wear latex gloves when servicing.
DO NOT DISPOSE OF FLUID IN THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
BRAKE FLUID
WARNING
Brake fluid can damage plastic, rubber or painted parts. When servicing the brake system, protect all
such parts with a clean cloth.
Always wear safety glasses when servicing the brake system.
Brake fluid is highly irritant. Avoid contact with the eyes.
In case of contact with the eyes, rinse thoroughly with cool, clean water and immediately seek medical
attention.
KEEP AWAY FROM CHILDREN.
GENERAL INFORMATION
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Griso V1100
HYDROGEN GAS AND BATTERY ELECTROLYTE
DANGER
The battery electrolyte is a toxic, caustic substance containing sulphuric acid and thus able to cause
severe burns in case of contact.
Wear close-fitting gloves and protective clothing when handling this fluid.
In case of contact with the skin, rinse thoroughly with fresh water.
Always use eye protection as even a very small amount of the battery fluid can cause blindness. If
battery fluid comes in contact with the eyes, flush thoroughly with water for fifteen minutes and
contact an eye specialist immediately.
If battery fluid is swallowed accidentally, drink plenty of water or milk. Seek medical attention
immediately and keep drinking milk of magnesia or vegetable oil in the meantime.
The battery gives off explosive gases. Keep the battery well away from any sources of ignition, such
as flames, sparks, or any heat sources; do not smoke near the battery.
Make sure the area is well ventilated when servicing or refilling the battery.
KEEP AWAY FROM CHILDREN.
Battery fluid is corrosive.
Avoid spillage. Take special care not to spill battery fluid on plastic parts.
Make sure that the electrolyte fluid you are using is the suitable type for your battery.
GENERAL PRECAUTIONS AND INFORMATION
Follow these instructions closely when repairing, disassembling or reassembling the motorcycle or its components.
DANGER
Using bare flames is strictly forbidden when working on the motorcycle. Before servicing or
inspecting the motorcycle: stop the engine and remove the key from the ignition switch; allow for the
engine and exhaust system to cool down; where possible, lift the motorcycle using adequate
equipment placed on firm and level ground. Be careful of any parts of the engine or exhaust system
which may still be hot to the touch to avoid scalds or burns.
Never put mechanical parts or other vehicle components in your mouth when you have both hands
busy. None of the motorcycle components are edible. Some components are harmful to the human
body or toxic.
Unless expressly indicated otherwise, reassemble the units by repeating the disassembly operations
in reverse order. Where a procedure is cross-referred to relevant sections in the manual, proceed
sensibly to avoid disturbing any parts unless strictly necessary. Do not use polishing pastes on matt
paints.
Never use fuel instead of solvent to clean the motorcycle.
Do not clean rubber or plastic parts or the seat with alcohol, petrol or solvents. Use only water and
mild soap.
Always disconnect the battery negative (-) lead before soldering any electrical components.
When two or more persons service the same motorcycle together, special care must be taken to avoid
personal injury.
For further warnings, see DANGEROUS ELEMENTS
BEFORE DISASSEMBLING ANY COMPONENTS
• Clean off all dirt, mud, and dust and clear any foreign objects from the vehicle before disassembling any
components.
• Use the model-specific special tools where specified.
DISASSEMBLING THE COMPONENTS
- Never use pliers or similar tools to loosen and/or tighten nuts and bolts. Always use a suitable spanner.
- Mark the positions of all connections (hoses, wiring, etc.) before disconnecting them. Identify each connection using
a distinctive symbol or convention.
- Mark each part clearly to avoid confusion when refitting.
- Thoroughly clean and wash any components you have removed using a detergent with low flash point.
- Mated parts should always be refitted together. These parts will have seated themselves against one another during
running as a result of normal wear and tear and should never be mixed up with other similar parts when refitting.
- Certain components are matched-pair parts and should always be replaced as a set.
- Keep away from heat sources.
GENERAL INFORMATION
1 - 7
Griso V1100
REASSEMBLING THE COMPONENTS
DANGER
Never reuse a circlip or snap ring. These parts must always be replaced with new ones once they have
been removed.
When fitting a new circlip or snap ring, open the ends just enough to allow fitting to the shaft.
Make a rule to check that a newly fitted circlip or snap ring is fully housed in its groove.
Never use compressed air to clean bearings.
NOTE All bearings must run freely with no hardness or noise. Replace any bearings that do not meet these
requirements.
- Use ORIGINAL Moto Guzzi spare parts only.
- Use the specified lubricants and consumables.
- Where possible, lubricate a part before assembly.
- When tightening nuts and bolts, start with the largest or innermost nut/bolt and observe a cross pattern. Tighten
evenly, in subsequent steps, until the specified torque has been achieved.
- Replace any self-locking nuts, gaskets, seals, circlips or snap rings, O-rings, split pins, bolts and screws which have
a damaged thread.
- Lubricate the bearings abundantly before assembly.
- Make a rule to check that all components you have fitted are correctly in place.
- After repairing the motorcycle and after each service inspection, perform the preliminary checks, and then test ride
the motorcycle in a private estate area or in a safe area away from traffic.
- Clean all mating surfaces, oil seal edges and gaskets before assembly. Apply a thin layer of lithium grease along the
edges of oil seals. Fit oil seals and bearings with the marking or serial number facing outwards (in view).
ELECTRICAL CONNECTORS
Disconnect electrical connectors as follows: failure to follow these instructions can seriously damage the connectors and
the wiring.
Press the special safety hooks, where fitted.
WARNING
Never separate two connectors by pulling on the wiring.
• Grasp both connectors and pull them in opposite directions until they become separated.
• Remove dirt, rust, moisture, etc., from inside the connectors with compressed air.
• Ensure that the wires are securely crimped to the terminals inside each connector.
NOTE A connector will fit properly only in the matching connector and when inserted in the correct fitting position.
• Reconnect the two connectors. Ensure that they are correctly coupled (if fitted with hooks, they should click audibly
into place).
TIGHTENING TORQUES
DANGER
Always remember that the tightening torques of all wheel, brake, wheel shaft and other suspension
parts are essential to ensuring safe operation of the motorcycle and must be set to the indicated
values. Ensure that these values are always within the specified limits.
Regularly check the tightening torques on all fastenings, and always use a torque wrench when fitting
them.
Failure to observe these instructions can result in parts loosening or coming away, thus jamming a
wheel or creating other problems which would affect the handling of the motorcycle, potentially
resulting in serious injury or death.
GENERAL INFORMATION
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Griso V1100
1.3 DANGEROUS ELEMENTS
1.3.1 WARNINGS
FUEL
DANGER
The fuel used to operate engines is highly flammable and becomes explosive under particular
conditions.
Refuelling and maintenance operations should be carried out in a well-ventilated area, with the engine
off.
Do not smoke when refuelling or in the proximity of sources of fuel vapours. Avoid contact with bare
flames, sources of sparks or any other source which may ignite the fuel or lead to explosion.
Take care not to spill fuel out of the filler, as it may ignite when in contact with hot engine parts.
In the event of accidental fuel spillage, ensure that the affected area is fully dry before starting the
engine. Fuel expands from heat and when left under direct sunlight.
Never fill the fuel tank up to the rim. Tighten the filler cap securely after each refuelling.
Avoid contact with the skin. Do not inhale vapours. Do not swallow fuel. Do not transfer fuel between
different containers using a hose.
DO NOT DISPOSE OF FUEL IN THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
Use only premium grade unleaded petrol, min. O.N. 95 (RON) and 85 (MON).
LUBRICANTS
DANGER
Correct lubrication is essential to the safety of the motorcycle.
Failure to maintain the lubricant level or the use of incorrect, old or dirty lubricant can cause the
engine or transmission to seize, resulting in accident, serious injury or death.
Prolonged or repeated contact with gear fluid may cause severe skin damage.
Wash your hands thoroughly after use.
Do not dispose of oil in the environment.
For disposal, contact the nearest waste oil reclamation firm or the supplier.
WARNING
Avoid spillage when filling the vehicle with oil. Immediately clean up any spilt oil, as it can damage
painted parts.
Oil on the tyres can make them very slippery and dangerous to use.
In case of leaks, do not use the motorcycle. Identify the cause of the leak and repair it.
ENGINE OIL
DANGER
Prolonged or repeated contact with engine oil may cause severe skin damage.
Wash your hands thoroughly after handling.
Do not dispose of oil in the environment.
For disposal, contact the nearest waste oil reclamation firm or the supplier.
Wear latex gloves when servicing.
FRONT FORK FLUID
DANGER
Front suspension response can be modified to a certain extent by changing damping settings and/or
selecting a particular grade of oil. Standard oil viscosity: SAE 20 W. Choose suitable oil grades
according to the desired set-up (choose SAE 5W for a softer suspension, 20W for a stiffer
suspension).
The two grades can also be mixed in varying solutions to obtain the desired response.
GENERAL INFORMATION
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Griso V1100
BRAKE FLUID
NOTE This vehicle is fitted with front and rear disc brakes. Each brake system is operated by an independent hydraulic
circuit. The information provided below applies to both brake systems.
DANGER
Do not drive the vehicle if the brakes are worn or not operating correctly. The brakes are the vehicle’s
most important safety component and using the vehicle with the brakes in less than perfect operating
condition comprises a high probability of traffic accident, which can result in serious injury or death.
The brakes are significantly less effective on a wet road surface.
DANGER
If the road surface is wet, maintain a double braking distance, as both the brakes and the grip of the
tyres are significantly less effective in such conditions.
Water on brakes, whether due to a recent wash or picked up from a wet road surface, puddles or
drains, can result in significantly reduced brake efficiency.
Failure to observe these instructions can result in serious accidents, with the risk of serious personal
injury or death.
The brakes are essential to your safety. Do not drive the vehicle if the brakes on not in perfect
operating condition.
Always check the brakes before riding the motorcycle.
Brake fluid is an irritant. Avoid contact with the eyes or skin.
In the event of accidental contact, wash affected body parts thoroughly. In the event of accidental
contact with the eyes, contact an eye specialist or seek medical attention.
DO NOT DISPOSE OF BRAKE FLUID IN THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
Avoid spillage. Brake fluid can damage plastic or painted parts.
DANGER
Do not use brake fluids other than the specified type. Never mix different types of fluids to top up the
level, as this will damage the brake system.
Do not use brake fluid from containers which have been kept open or in storage for long periods of
time.
Any sudden changes in slack or hardness in the brake levers are warning signs of problems with the
hydraulic circuits.
Make sure that the brake discs and brake linings have not come in contact with oil or grease. This is
particularly important after servicing or inspections.
Make sure the brake lines are not twisted or worn.
Avoid accidental entry of water or dust into the circuit.
Wear latex gloves when servicing the hydraulic circuit.
DISC BRAKES
DANGER
The brakes are the vehicle’s most important safety component
To ensure your personal safety, they must be in perfect working order and should be checked before
every ride.
A dirty disc soils the pads.
Dirty pads must be replaced. Dirty or oily discs must be cleaned with a high-quality degreasing
product.
If the vehicle is often used on wet road surfaces or on dusty or rough tracks, or if used in competition,
reduce the service intervals by half.
Check brake pads for wear.
When the brake pads are worn, the fluid level lowers to compensate for the wear.
The front brake fluid reservoir is on the right-hand side of the handlebar, next to the front brake lever.
The rear brake fluid reservoir is located under the right-hand side fairing.
Do not use the vehicle if the brake system leaks fluid.
GENERAL INFORMATION
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Griso V1100
TYRES
WARNING
An over-inflated tyre results in a hard, uncomfortable and less secure ride.
Over inflation also affects grip, especially on curves and wet surfaces.
An under-inflated tyre (insufficient pressure) can slip on the wheel rim, resulting in loss of control.
Under inflation also affects grip and handling, as well as braking efficiency.
Tyre changing and repair, and wheel servicing and balancing are delicate operations. They should be
carried out using adequate tools and are best left to experienced mechanics.
New tyres may be covered with a thin layer of protective coating which is slippery. Drive carefully for
the first few kilometres (miles).
Never use rubber treatment products on the tyres.
In particular, do not allow the tyre to come in contact with liquid fuel, which rapidly deteriorates the
tyre rubber.
In case of contact with oil or fuel, do not clean but change the tyres.
DANGER
Some of the factory-assembled tyres of this vehicle are provided with wear indicators.
There are various types of wear indicators.
For more information on how to check the wear, contact your Dealer.
Check wear visually and have the tyres replaced when they are worn.
If a tyre deflates during a ride, do not attempt to continue the trip.
Avoid sudden braking or steering manoeuvres, and do not decelerate abruptly.
Slowly decelerate and move to the edge of the road braking with the engine until you come to a
standstill.
Failure to observe these instructions can result in accidents, with the risk of serious personal injury or
death.
Never use tube tyres on tubeless tyre rims, or vice versa.
GENERAL INFORMATION
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Griso V1100
1.4 RUNNING-IN
1.4.1 RUNNING-IN
Proper engine running in is essential to preserving engine life and performance over time.
Twisty roads and gradients are ideal for breaking in engine, suspension and brakes effectively.
Varying speed frequently is also recommended.
This will vary the amount of stress placed on vehicle components continuously, allowing engine parts to cool down when
less stressed.
While it is important to put a certain amount of stress on engine components during the running-in period, it is equally
important to spare the engine at this stage in the vehicle’s life.
WARNING
Top acceleration performance is only obtained after covering the first 2000 km (1243 mi).
Follow these recommendations:
• Do not open the throttle completely when the engine is running at low speed, both during and after the running-in
period.
• Until you have covered the first 100 km (62 mi), use the brakes gently and avoid harsh, prolonged braking. This will
help the brake pads bed in properly against the brake disc.
• During the first 1000 km (621 mi), never exceed 5000 rpm (see table).
WARNING
After covering the first 1000 km (621 mi), perform the checks listed in the "After running-in" column
(see REGULAR SERVICE INTERVALS CHART) to avoid personal injury to yourself or third persons, or
vehicle damage.
• After the first 1000 km (621 mi) and until covering 2000 km (1243 mi), drive more briskly, varying speed and using
maximum acceleration for just a few seconds, in order to ensure better component coupling; never exceed 6000
rpm (see table).
• After the first 2000 km (1243 mi) you may run the engine harder, however, without exceeding the maximum rpm
allowed (7600 rpm).
Recommended maximum rpm
Mileage km (mi) rpm
0-1000 (621) 5000
1000-2000 (621-1243) 6000
Over 2000 (1243) 7600
GENERAL INFORMATION
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Griso V1100
1.5 POSITION OF THE SERIAL NUMBERS
1.5.1 POSITION OF THE SERIAL NUMBERS
These numbers are necessary for vehicle registration.
NOTE Altering the vehicle's identification numbers is
punishable by law with heavy fines and penalties. Altering
the frame number voids the warranty.
This number consists of figures and letters as shown in the
example below.
ZGULP00005MXXXXXX
Key:
ZGU: WMI (World manufacture identifier) code;
LP: model;
000: version;
0: free digit
5 year of manufacture variable (5 = 2005)
M: manufacturing facility (M= Mandello del Lario);
XXXXXX: progressive number (6 digits);
FRAME NUMBER
The frame number is stamped on the right-hand side of the
headstock.
ENGINE NUMBER
The engine number is stamped on the left-side, near the
engine oil level plug.
GENERAL TECHNICAL INFORMATION
2 - 1
Griso V1100
GENERAL TECHNICAL INFORMATION 2
GENERAL TECHNICAL INFORMATION
2 - 2
Griso V1100
SUMMARY
2.1 TECHNICAL INFORMATION............................................................................................................................ 3
2.1.1 TECHNICAL DATA.................................................................................................................................... 3
2.1.2 SCHEDULED MAINTENANCE CHART .................................................................................................... 5
2.1.3 LUBRICANT TABLE.................................................................................................................................. 7
2.1.4 TIGHTENING TORQUE SETTINGS ......................................................................................................... 8
2.1.5 SPECIAL TOOLS .................................................................................................................................... 12
2.1.6 ARRANGEMENT OF THE MAIN ELEMENTS......................................................................................... 14
2.1.7 LOCATION OF INSTRUMENTS/CONTROLS......................................................................................... 16
2.2 MAINTENANCE OPERATIONS ..................................................................................................................... 18
2.2.1 CHANGING ENGINE OIL AND OIL FILTER ........................................................................................... 18
2.2.2 TRANSMISSION OIL............................................................................................................................... 20
2.2.3 GEARBOX FLUID.................................................................................................................................... 21
2.2.4 CLEANING THE AIR FILTER .................................................................................................................. 22
2.2.5 ADJUSTING VALVE CLEARANCE......................................................................................................... 24
2.2.6 FRONT BRAKE ....................................................................................................................................... 26
2.2.7 REAR BRAKE.......................................................................................................................................... 28
2.2.8 GENERATOR BELT TENSIONING......................................................................................................... 31
GENERAL TECHNICAL INFORMATION
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Griso V1100
2.1 TECHNICAL INFORMATION
2.1.1 TECHNICAL DATA
DIMENSIONS
Max. length 2260 mm (88.98 in.)
Max. width 880 mm (34.64 in.)
Max. height 1070 mm (42.12 in.) (excluding the rear/view mirrors)
Seat height 800 mm (31.49 in.)
Wheelbase 1554 mm (61.18 in.)
Minimum ground clearance 185 mm (7.28 in.)
Weight in running order 240 kg (529.1 lb)
ENGINE
Type twin-cylinder, 90° V transversal, 4-stroke engine
Number of cylinders two
Cylinder arrangement V, 90°
Total displacement 1064 cu cm (65 cu in)
Bore/stroke 92 x 80 mm (3.6 x 3.1 in).
Compression ratio 9.6 : 1
Starting electric
Engine idling speed 1100 ± 100 rpm
Clutch dry, twin disc
Lubricating system System under pressure, adjustment by valves and vane pump
Air filter cartridge, dry
Cooling system air cooled
TIMING SYSTEM
Timing diagram: 2 valves, with rods and rocker arms
Values with inspection clearance between
rocker arms and valve
intake 0.10 mm (0.0039 in.)
exhaust 0.15 mm (0.0059 in.)
CAPACITIES
Fuel (reserve included) 17.2 litres
Fuel reserve 3.3 litres
Engine oil Engine oil and oil filter change 3600 cu. cm (219 cu in)
Gearbox fluid 500 cu cm (30.5 cu in)
Transmission fluid 380 cu cm (23.2 cu in)
Fork oil 520±2.5 cu cm (31.7 ± 1.5 cu in) (per leg)
Seats 2
Max. vehicle load 210 kg (462.97 lb) (rider + passenger + luggage)
TRANSMISSION SYSTEM
primary drive gear, ratio: 24/35 = 1:1.4583
gearbox Mechanic, with 6 speeds, controlled by a pedal on engine left side
overall gear ratios:
1st gear 17/38 = 1:2.2353
2nd gear 20/34 = 1:1.7
3rd gear 23/31 = 1:1.3478
4th gear 26/29 = 1:1.1154
5th gear 31/30 = 1:0.9677
6th gear 29/25 = 1:0.8621
final drive with cardan joint
ratio 12/44 = 1:3.6667
FUEL SYSTEM
Type Electronic injection (Weber – Marelli) with stepper motor
Choke Ø 36 mm (1.417 in.)
Fuel Premium grade unleaded petrol, minimum octane rating 95 (RON)
and 85 (MON).
FRAME
Type Tube, with double cradle in high-strength steel
Steering head angle 26°30’
Trail 108 mm (4.25 in.)
GENERAL TECHNICAL INFORMATION
2 - 4
Griso V1100
SUSPENSIONS
Front Hydraulic upside-down telescopic fork Ø 43 mm (1.69 in); spring
preload, compression and rebound damping are adjustable.
Wheel travel 120 mm (4.72 in.)
Rear single-sided with progressive linkage, monoshock with adjustable
rebound and compression damping and spring preload
Wheel travel 110 mm (4.33 in.)
BRAKES
Front Twin stainless steel floating disc - Ø 320 mm (12.60 in), callipers with
four separate opposed pistons
Rear Stainless steel disc Ø 282 mm (11.10 in)
WHEEL RIMS
Type 3 hollow spokes in aluminium alloy, chill cast
Front 3.5" x 17”
Rear 5.5" x 17”
TYRES
Type Dunlop D208 RR - Metzeler rennsport - Pirelli diablo corsa -Michelin
pilot power
Front Size: 120/70 - ZR 17” 58 W
Inflating pressure: 2.3 atm (230 kPa)
Inflating pressure with passenger: 2.3 atm (230 kPa)
Rear Size: 180/55 - ZR 17” 73 W
Inflating pressure: 2.5 atm (250 kPa)
Inflating pressure with passenger: 2.7 atm (270 kPa)
SPARK PLUGS
Internal (long life) NGK PMR8B
External NGK BPR6ES
Electrode gap 0.6 – 0.7 mm (0.024 – 0.028 in.)
ELECTRIC SYSTEM
Battery 12 V – 18 Amp/h
Main fuses 30 A
Auxiliary fuses 3 A – 15 A – 20 A
Generator (with permanent magnet) 12 V – 550 W
BULBS
Parking light 12 V – 5 W
Low beam bulb/high beam 12 V – 55 W / 60W H4
Turn indicator light 12 V – 10 W
Stop/rear parking lights LED
Instrument panel lighting LED
Number plate light 12 V – 5 W
WARNING LIGHTS
Turn indicators LED
Oil pressure LED
Neutral LED
Side stand down LED
High beam LED
Fuel reserve LED
Alarm, gear shift indicator LED
GENERAL TECHNICAL INFORMATION
2 - 5
Griso V1100
2.1.2 SCHEDULED MAINTENANCE CHART
OPERATIONS TO BE PERFORMED BY THE Moto Guzzi Authorised Dealer (AND CAN BE PERFORMED BY THE
USER AS WELL).
1 = check and clean, adjust, lubricate or change, if necessary;
2 = clean;
3 = replace;
4 = adjust.
NOTE Perform maintenance operations more frequently if the vehicle is used in rainy and dusty areas, on uneven
ground, or for racing.
(*) = Change every 5000 Km (3125 mi), if used for racing
(**) = Check every two weeks or at indicated intervals.
Component
After running-in
[1500 km (621 mi)]
Every 10000 km
(6250 mi) or 12
months
Every 20000 km
(12500 mi) or 24
months
External plugs (*) - 3 Engine oil filter (*) 3 3 Fork 1 - 1
Headlight beam direction - operation - 1 Light system 1 1 Safety switches 1 1 Brake fluid - 1 Engine oil 3 3 Tyres 1 1 Tyre pressure (**) 4 4 Idling rpm 4 4 Battery terminal tightening 1 - Head bolt tightening 4 - Engine oil pressure warning light at every starting: 1
Brake pad wear
1
before every trip and
every 2000 km (1250 mi): 1
Emptying the oil drain hose from filter box end Every 5000 km (3125 mi): 2
GENERAL TECHNICAL INFORMATION
2 - 6
Griso V1100
OPERATIONS TO BE PERFORMED BY THE Moto Guzzi Authorised Dealer.
1 = check and clean, adjust, lubricate or change, if necessary;
2 = clean;
3 = replace;
4 = adjust.
NOTE Perform maintenance operations more frequently if the vehicle is used in rainy and dusty areas, on uneven
ground, or for racing.
(*) = Change every 5000 Km (3125 mi), if used for racing
(**) = Check every two weeks or at indicated intervals.
Component
After running-in
[1000 km (621 mi)]
Every 10000 km
(6250 mi) or 12
months
Every 20000 km
(12500 mi) or 24
months
Gearbox fluid 3 3 Idle mixture (CO) - 1 Transmission and control cables 1 1 Steering bearings and steering play 1 1 Wheel bearings - 1 Brake discs 1 1 Air filter - 1 3
Vehicle general operation 1 1 Brake systems 1 1 Brake fluid - - 3
Front fork fluid after the first 10000 km (6250 mi)
and then every 20000 km (12500 mi): 3
Fork oil seals after the first 30000 km (18750 mi)
and then every 20000 km (12500 mi): 3
Brake pads every 2000 km (1250 mi): 1 - if worn: 3
Adjusting the valve clearance 4 4 Wheels / Tyres 1 1 Tightening of nuts and bolts 1 1 Battery terminal tightening 1 - Cylinder synchronisation 1 1 Suspensions and trim 1 - 1
Final transmission fluid 3 3 Fuel hoses - 1 Every four years: 3
Brake lines - 1 Every four years: 3
Clutch wear (*) - 1 Internal spark plugs - - 4
Generator belt every 20000 km (12500 mi): 4, every 50000 km (31250 mi): 3
Head stud bolt tightening 4 - Exhaust pipe flange bolts 1 - -
GENERAL TECHNICAL INFORMATION
2 - 7
Griso V1100
2.1.3 LUBRICANT TABLE
LUBRICANT PRODUCT
Engine oil
RECOMMENDED: RACING 4T 5 W 40
As an alternative to recommended oils, top brand oils meeting or exceeding
CCMC G-4 A.P.I. SG specifications can be used.
Transmission fluid
RECOMMENDED: TRUCK GEAR 80 W 90
Gearbox fluid
RECOMMENDED: ROTRA MP/S 85 W 90
Front fork fluid
RECOMMENDED: F.A. 5W or F.A. 20W, as an alternative
FORK 5W or FORK 20W.
Bearings and other
lubrication points
RECOMMENDED:
BIMOL GREASE 481, AUTOGREASE MP or
GREASE SM2.
As an alternative to recommended grease, use top brand rolling bearing
grease that will resist a temperature range of -30°C to +140°C (-22°F to
+284°F), with dripping point 150°C to 230°C (302°F to 446°F), high
corrosion protection, good resistance to water and oxidisation.
Battery terminals
Use neutral grease or Vaseline.
Brake fluid
RECOMMENDED:
Autofluid FR. DOT 4 (the braking system is also
compatible with DOT5); or BRAKE 5.1 DOT 4 (the braking system
is also compatible with DOT 5).
As an alternative to the recommended product, top brand brake fluid
meeting or exceeding SAE J1703, NHTSA 116 DOT 4, ISO 4925
specifications for synthetic brake fluid can be used.
NOTE Use new brake fluid only. Do not mix different makes or types of oil
without having checked bases compatibility.
GENERAL TECHNICAL INFORMATION
2 - 8
Griso V1100
2.1.4 TIGHTENING TORQUE SETTINGS
DESCRIPTION Q.ty
SCREW / NUT
TIGHTENING
TORQUE
(Nm)
NOTE
FRAME
Engine to frame front fastening 2 M12x50 80
Gearbox to frame fastener (M12x250 + M12x230) 1+1 M12 50
Gearbox rh plate fastener 2 M8X30 25
Blow-by sec.plate fastener 1 M6X16 10
Coil plate fastener 4 M6x20 10
Electronic control unit fastener 2 M6x20 10
Bushes to electronic control unit fastener 2 M6X35 10 Loctite 243
Rear reservoir rubber blocks to frame fastener 2
Silentbloc
k M6
Man Loctite 243
A
ir box pins fastener 2 M6 10
Lh and rh footrest plate to frame top fastener 2 + 2 M8X30 25 stainl.steel – A4 –80
Lh and rh footrest plate to frame bottom fastener 2+2 M8x75 18 stainl.steel – A4 –70
Brake switch to plate fastener 1 M8 Man. Pitch 1
Chromed ring to plate fastener 6 M5x10 6
Cable rings to rh footrest plate fastener 3 M5x10 6
FOOTRESTS AND LEVERS
Footrest rubber mat fastener 8 M6x12 10
Rider footrest safety pin M8 2 M8 25
Passenger footrests support to side plates fastener 4 M10X30 38 stainl.steel – A4 –70
Rider heel guard to plates fastener 4 M5X15 6
Passenger heel guard fastener 4 M4X10 3
Linkage fastening nut 1+1 M6 10 Self-locking nut
Brake/gear change lever pin fastener 1+1 M6X16 10
Pre-selector lever fastener 1 M6x20 10
Brake/gear change lever pin fastener 1+1 M8 15 Apply Loctite 243
SIDE STAND
Stand plate to engine top fastener 1 M10X25 50
Stand plate to engine bottom fastener 2 M8X25 25
Side stand securing pin 1 M10x1.25 10
Switch screw 1 M6x20 10 Loctite 243
Lock nut 1 M10x1.25 30
Stand cable guide to engine fastener 1 M10 50
Side lever section fastener 2 M6X16 10 Loctite 243
GENERAL TECHNICAL INFORMATION
2 - 9
Griso V1100
DESCRIPTION Q.ty
SCREW / NUT
TIGHTENING
TORQUE
(Nm)
Note
SWINGING ARM
Swinging arm clamp to bush fastener 2 6X25 10
Swinging arm to bevel gears fastener 4 M10x35 50
Linkage to bevel gears fastener 1 M10x50 50
Linkage to frame fastener 1 M10x50 50
Swinging arm shaft to swinging arm fastener 1 M12x1.25 60
Preload bush to swinging arm shaft fastener 1 M25x1.5 10
FRONT SUSPENSION
FRONT FORK
Tube stop plate to bottom yoke fastener 2 M5x16 6
Fork leg to steering head fastener 2 M8X30 20 Stainl.steel A4 cl. 80
Stainl.steel A4 cl. 80
22 First tighten top screw to 22 Nm
22 Then tighten bottom screw to 22 Nm
Fork leg to bottom yoke fastener 6 M8X30
18 Then tighten centre screw to 18 Nm
Steering tube ring nut 1 M35x1 40
Steering tube lock ring nut 1 M35x1 Man. 0 to 90 degrees
Steering head plug 1 M29x1 100 Use a torque wrench
Fork clamps blanking 2+2 M8X40 25
REAR SUSPENSION
SHOCK ABSORBER
Shock absorber to frame fastener 8.8 1 M10x80 50
CONNECTING RODS
Double connecting rod/shock absorber fastene
r
10.9
1 M10x47 40
Single connecting rod/double connecting rod
fastener 10.9
1 M10x95 50
Single connecting rod to frame fastener 8.8 1 M10x85 50
Double connecting rod/swinging arm fastener 10.9 1 M10x82 50
AIR BOX – BLOW BY
Expansion tank spacer to engine fastener 1 M6 10
Blow by expansion tank to spacer fastener 1 M6 10
A
ir box to frame fastener 2 M6x20 10
EXHAUST
Exhaust pipe to engine fastener 4 M8x1.25 25
Silencer connecting tube to frame fastener 1 M8X50 25
Silencer to footrest support fastener 2 M8X45 25
Protection to connection tube fastener 1 M6 10
Oxygen sensor fastener 1 M18x1.5 38
Clamp fastener 3 M6 10
GENERAL TECHNICAL INFORMATION
2 - 10
Griso V1100
DESCRIPTION Q.ty
SCREW / NUT
TIGHTENING
TORQUE
(Nm)
Note
FRONT WHEEL
Wheel shaft nut 1 M25x1.5 80
REAR WHEEL
Disc fastener 6 M8x20 25
Rear wheel fastener 4 M12x65 110
BRAKING SYSTEM
Front brake rh and lh callipers fasteners 2+2 M10x28 50
REAR SYSTEM
Rear brake calliper fastener 2 M10X30 50
Rear brake fluid reservoir fastener 1 SWP5x20 3
Rear brake reservoir support to plate fastener 1 M6X16 10
Rear brake lever lock nut 1 M6 Man.
Brake master cylinder fasteners 2 M6x20 10 Apply Loctite 243
HANDLEBAR AND CONTROLS
Handlebar lower U-bolts to steering head fastener 2 M10X40 50
Handlebar upper U-bolts fastener 2+2 M8X30 25 stainl.steel – A4 –-80
Counterweights fasteners 2 M6x60 10
Brake and clutch master cylinder U-bolts fasteners 2+2 M6 10
Rh and Lh dip switch fasteners 2 M5 1.5
Clutch master cylinder to gearbox fastener 3 M6 10
Mirror 1+1 M10 Man.
ELECTRIC SYSTEM
Coil fastener 8 M4x25 2
Horn fastener 2 M8 15
Odometer sensor to bevel gears fastener 2 M4X10 3
INSTRUMENT PANEL AND HEADLIGHT
Instrument panel support to headlight support
fastener
2 M6X16 10
Instrument panel support to steer.head fastener 2 M6X16 10
Instrument panel fasteners 3 SWP5x14 3
Headlight support to bottom yoke fastener 2 M8x35 25
Front+rear turn indicators fasteners 2+2 M6
Headlight fasteners 2 M8X30 15
Tail light to tail guard fastener 4 SWP5x14 3
GENERAL TECHNICAL INFORMATION
2 - 11
Griso V1100
DESCRIPTION Q.ty
SCREW / NUT
TIGHTENING
TORQUE
(Nm)
Note
FUEL TANK
FUEL PUMP FLANGE
Tank breather fitting 2 M6 6
Pump support to tank fastener 6 M5x16 6
TANK
Union to tank fastener 4 M5x16 5
Plug ring nut to tank fastener 4 M5X15 5
Screws to plug ring nut (aesthetic) 4 M5X15 5
Tank to frame front fastening 2 M6X35 10
Battery box and tank to frame rear fastener 2 M6X25 6
BODYWORK
FRONT
Front mudguard fastener 2+2 M5 6
Electronic control unit fastener 2 M5 6
Conveyor to frame upp. front fastener 1+1 M5 Man
Conveyor to frame low. front fastener 1+1 M5
Man
Conveyors to frame rear fastener 1+1 M5
Man
Conveyors to conveyor clos.fastener 2X3
self-
tapping
Man
REAR
Cat's eye to support fastener 1 M5 4
Cat's eye support to number plate holder fastener 2 M5x12 4
Reinforcement to number plate holder and light
fastener
1
M5 4
Number plate holder to low.clos. fastener 2 self-tapp. Man
Tail guard low.clos. to frame fastener 4 M8x35 25
Fuse bracket and relay supp. fastener 4 M5 4
ACCESSORIES
Ignition switch fastener – shear bolt 2 M8x28 Shear completely
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