MOTO GUZZI 1200 SPORT Spezifikationen Seite 1

SERVICE STATION MANUAL9810921200 SPORT 4V

IN ENSURING VEHICLE SAFETY AND MUST COMPLY WITH SPECIFIED VALUES. CHECK THETIGHTENING TORQUES OF FASTENING ELEMENTS ON A REGULAR BASIS AND ALWAYS USEA

•Replace bearings if necessary and re-move the clutch shaft.See alsoRemoving the gearboxRemoving the primary shaft•Remove the main shaft.•Operate on t

•Remove the circlip.•Remove the gear of the third and fourthgears.•Remove the circlip and collect theshoulder washer.•Remove the gear of the fifth gea

•Heat the shaft with a specific heaterand remove the helical transmissiongear.Removing the secondary shaft•Remove the transmission shaft.•Operate on t

•Remove the circlip.•Remove the gear of the sixth gear.•Remove the circlip and collect theshoulder washer.•Remove the gear of the fourth gear andcolle

•Remove the gear of the third gear andcollect the ball bearing cage and theshoulder washer.•Remove the circlip.•Remove the gear of the fifth gear.•Rem

Checking the primary shaftMeasure coaxiality of the main shaft with a dialgauge and a centring device and replace it if notcomplying with specificatio

Checking the forksNOTETHE FOLLOWING PROCEDURE IS VALID FOR ALL GEARBOX FORKS.•Check the transmission fork cam roller«1» and the transmission fork toot

TO REFIT, FOLLOW THE SAME INSTRUCTIONS AS FOR REMOVAL BUT IN REVERSE ORDER.REMEMBER TO REPLACE ALL SEALING RINGS, CIRCLIPS AND SAFETY RINGS PREVIOUSLY

GeneratorKey:1. Alternator2. Spacer3. Screw4. Screw5. Nut6. Belt7. Generator control pulley8. Nut9. Washer10.Magneto flywheel cotter11.Screw12.NutEngi

Removing the generator•Remove the fuel tank.•Remove the control unit from its seat.•Disconnect the alternator connectors.•Undo and remove the five scr

This number consists of numbers and letters, as inthe example shown below.ZGULPR000YMXXXXXXKEY:ZGU: WMI (World manufacturer identifier) code;LP: model

•Loosen the nut and undo the set screwso that the alternator slides down.•Completely loosen and remove thescrew.•Remove the belt and the alternator wi

•Undo and remove the eight screws.•Undo and remove the two screws.•Undo and remove the two screws.1200 SPORT 4V EngineENG - 111Revente Interdite - Rev

•Remove the alternator frame.•Remove the sealing ring if necessary.See alsoFuel tankTensioning the belt•Remove both side fairings of the fuel tank.•Re

•Remove the engine oil radiator.•Disconnect the horn connectors.•Remove the support plate of the en-gine oil radiator.•Remove the four fixing screws o

•Remove the timing system cover.•Loosen the lock nut of the set screw.•By using the belt tensioning tools, ten-sion the belt to the prescribed torque.

•Replace the gasket and place the al-ternator frame using the front cover in-sertion cone.•Remove the insertion cone afterwards.Specific tooling05.91.

•Position the lower pulley and thespacer.•Tighten the nut to the prescribed tor-que.•Position the alternator and the timingsystem belt.•Position the s

•Using the belt tensioning tool, tensionthe belt to the prescribed torque andtighten the set screw.•Remove the belt tensioning tool.•Lock the set scre

Starter motorRemoving the starter motor•Undo and remove the two screws andcollect the washers.•Slide off the starter motor.Clutch sideEngine 1200 SPOR

Disassembling the clutchKey:1. Complete clutch2. Clutch3. Clutch bell4. TCEI screw5. Clutch disc6. Crown7. TCEI screw8. Clutch pressure plate9. Ring10

Specification Desc./QuantityCompression ratio 11: 1Electric starterIdle speed 1100 ± 100 rpmClutch hydraulic single plate dry clutch with integrated f

20.TE flanged screw•Remove the complete gearbox.•Undo and remove the six screws.•Remove the start-up crown gear.•Remove the clutch bell and the fricti

•Undo and remove the six screws andcollect the belleville springs.•Remove the clutch disc.See alsoRemoving the gearboxChecking the clutch actuatorIf t

020678Y Tool for clutch rod checkingCLUTCH CONTROL ROD SELECTIONSpecification Desc./QuantityProtrusion: 9.8 - 11.2 mm (0.386 - 0.441 in) Clutch contro

•Once the centring tool is fitted, lock theplate with the snap ring.•Undo and remove the two screws fixingthe tool.•Remove the special tool.•Place the

Head and timingKey:1. Right cylinder head2. Stud bolt3. Cylinder head gasket4. Right rocking lever support5. Screw6. Pin7. Nut8. Right exhaust, left i

20.TE flanged screw21.O-ring22.Complete breather cover23.TBEI screw24.Timing system chain25.Chain guide slider26.Chain tensioner pad27.Chain tensioner

Removing the head coverNOTETHE OPERATIONS DESCRIBED BELOW REFER TO REMOVING ONLY ONE HEAD BUT APPLYTO BOTH HEADS.•Disconnect the spark plug tube.•Uns

•Unscrew and remove the screw.•Remove the timing system upper gearbulkhead.For the right head:•Unscrew and remove the chain ten-sioner cap.•Remove the

•Slide off the timing system gear fromthe chain to remove it from the cam-shaft.•Unscrew and remove the four nuts onthe stud bolts.•Remove the complet

•Collect the two head dowel pins.•Collect the gasket between the headand the cylinder.See alsoRemoving the head coverCylinder headRemoving the overhea

Specification Desc./QuantityInstrument panel lighting LEDLicense plate light 12V - 5 WTurn indicator warning light LEDNeutral gear warning light LEDAl

•Remove the camshaft.•Remove the bowls from the cam cap,and mark their position so as not inter-change them when refitting.See alsoRemoving the rocker

•Remove the two rocking levers fromthe cam cap.See alsoRemoving the cylinder headRemoving the valves•Remove the head.•Place the special tool on the up

The valve guides should be replaced only if the clearance between them and the stem cannot be elim-inated by simply replacing the valves.To refit the

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 cu

Installing the rocker arms•Fit the camshaft.•Fit the two rods.WARNINGMAKE SURE THAT THE NOTCH ON THE DIPSTICK BODYFACES THE ROCKING LEVER.•Place the t

Installing the overhead camshaftInstalling the overhead camshaft•Place the bowls in the cam tower, ifthose previously removed are refittedbe careful n

Removing the phonic wheel•Remove the generator and the timingsystem cover.•Unscrew and remove the nut and col-lect the washer.•Remove the timing syste

•Mark the timing chains so as not to in-vert the direction of rotation upon fit-ting.•Slide off the service shaft from thechains.•Remove both chains.S

•Partially fit the service shaft closingcap.•To screw the cap until it stops, use twoM6 flanged screws larger than the orig-inal screws.•Tighten the t

Cam timing•Fit the crankshaft and the service shafton the crankcase.•Fit the cylinders.•Turn the crankshaft until the left cylin-der piston reaches th

Wheels and tyresWHEELS AND TYRESSpecification Desc./QuantityType hollow 3-spoke rim in chilled cast aluminium alloyFront wheel rim 3.50" x 17&quo

•After shimming the timing sensor prop-erly, proceed to fit it.•Fit the washer and tighten the timingsystem gear fixing nut of the serviceshaft.•Place

•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 gea

Measuring air gap•Undo and remove the two screws andremove the sensor.•Insert a suitable plain washer on thesensor and note its thickness.•Place the s

Cylinder-piston assemblyKey:1. Right cylinder2. Piston3. Screw4. Top piston ring5. Middle piston ring6. Oil scraper piston ring7. Pin8. Snap ring9. Cy

Removing the cylinderNOTETHE OPERATIONS DESCRIBED BELOW REFER TO REMOVING ONLY ONE HEAD BUT APPLYTO BOTH HEADS.•Remove the head, the gasket betweenth

•Mark the piston crown on the exhaustside so as to remember the refitting po-sition.•Remove the piston.Fitting the pistonNOTETHE OPERATIONS DESCRIBED

•Insert the pin.•Insert the snap ring.Specific tooling020470Y Pin snap ring fitting toolInstalling the cylinderRIGHT CYLINDER•Fit the piston.•Remove t

020716Y Connecting rod locking•Remove the piston ring clamp tool andfinish positioning the cylinder.Specific tooling020674Y Piston ring clamp•Fit the

•Check that the oil in the left cylinderchain tensioner has been drained offby compressing it. If the operation isdifficult, use a pin drive to push t

Installing the cylinder head•Fit the valves in the head, if previouslyremoved.•Take the left cylinder piston to TDC andlock crankshaft rotation.•Deter

OIL SUMPName Torque in NmOil pipe on sump reduction (1) 20 Nm (14.75 lbf ft)Oil pipe on sump 20 Nm (14.75 lbf ft)Oil sump lower screw - TCEI M6x30 (4)

•Fix the head with the two screws.•Tighten nuts and screws to the prescri-bed torque operating diagonally and instages.•Loosen the valve set screws.•U

•Fit the gasket with the correct thick-ness between the head and the cylin-der.•Fit the right cylinder head.•Unscrew and remove the right chaintension

•Place the cap.•Tighten the two screws to the prescri-bed torque.•Also place the cap of the other head.•Adjust valve clearance.See alsoChecking the va

Crankcase - crankshaftRemoving the crankshaft•Remove the clutch.•Remove the tone wheel and the oilpump gear.•Working from the generator side, un-screw

•Remove the crankshaft afterwards.•Collect the shim washer from inside thecrankcase.See alsoDisassembling theclutchRemoving the phonic wheelDisassembl

Inspecting the crankshaft componentsCheck the surfaces of the main journals; if they arescored or oval-shaped, reface them (observing theundersize cha

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 connecting rods have a marked area forweight selection.The weight indicated in the chart includes screws,dowels and the bushing.CONNECTING ROD WEI

PAY ATTENTION TO CRANKSHAFT ROTATION WHEN ONLY THE CONNECTING RODS AREFITTED BECAUSE IT COULD HIT THE TWO LUBRICATION JETS INSIDE THE CRANKCASE.Instal

•Place the flywheel-side flange on thecrankshaft and check if the dowel pinwith the O-ring is correctly placed.•When fitting the flange on the crank-c

CHASSIS TO ENGINE UNITName Torque in NmM6x40 TCEI DA screw 8 -12 NmReduction 20 NmFUEL SUPPLY CONTROL UNITName Torque in NmM5x12 TCEI screw 6 -7 NmSta

Refitting the crankcase halvesIn case the lubrication jets are removed, replacethem with two new of the same type. Check thatthe O-ring is fitted on t

1. Oil cooling radiator2. Oil delivery pipe to heads3. Oil delivery pipe to radiator4. Oil pump body5. Oil pump gasket6. Rotor for lubrication7. Rotor

•Remove the nipple - oil pump fitting.•Bring the left cylinder piston to the TDCin combustion phase.•Mark a reference on the oil pump con-trol gear an

•Undo and remove the three screws.•Remove the oil pump.•Remove the gasket between thecrankcase and the oil pump.See alsoReplacementRemoving the genera

•Place the driving pin on the oil pumpshaft.•Place the gear on the oil pump shaft.•Place the washer on the oil pump shaft.•Tighten the nut to the spec

•Insert the joint in the oil pump.•Fit the nipple with the gasket on thecrankcase.•Tighten the nipple to the prescribedtorque.Removing the oil sumpNOT

•Undo and remove the fourteen screwsfixing the oil sump to the engine crank-case.•Undo and remove the four screws.•Remove the flange.Engine 1200 SPORT

•Undo and remove the two screws.•Remove both filters.•Unscrew and remove the plug.•Remove the thermostatic valve.•Unscrew and remove the pressure re-l

Refitting the oil sump•Place the pressure relief valve compo-nents correctly.•Screw the pressure relief valve plug.•Place the thermostatic valve.CHECK

•Tighten the thermostatic valve plug.•Place a new gasket between the crank-case and the flange.•Fit the flange.•Fix the flange with the four screws.•F

Name Torque in NmTube lock plate to steering base retainer 6 NmFork stem to lower / upper plate retainer 25 NmHeadstock ring nut 40 NmHeadstock counte

•Check that the O-rings are fitted on theoil pump.•Fit the cooling oil intake filter.•Fix both filters and tighten the twoscrews to the prescribed tor

•Place the oil sump.•Tighten the fourteen screws to the pre-scribed torque.•Add engine oil up to the correct level.1200 SPORT 4V EngineENG - 171Revent

INDEX OF TOPICSPOWER SUPPLY P SUPPRevente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

Circuit diagramKey:1. Full fuel tank2. Fuel pipe3. Throttle body4. Joint5. Three-way joint6. PipeInjection1200 SPORT 4V Power supplyP SUPP - 173Revent

DiagramKey:1 Control unit2 Ignition switch3 Battery4 Fuel pump5 Coils6 Instrument panel7 Air temperature sensor8. Throttle valve position sensor9 Inje

13 Lambda probe14 Fall sensorTHROTTLE BODY PIPES LAYINGPipes from the throttle body to the idle motorshould be laid so that the shaped part is inserte

•Turn on the scanner.•Screw the joints connecting the vacuometer pipes on the inlet pipe holes.•Connect the vacuometer pipes to the relative joints.•S

Otherwise, open only the screw withhigher depression, using the by-passscrews, to compensate.If there is a larger difference:•act on the set screw of

Iso screen pageISOThis screen page shows general data regardingthe control unit, for example software type, map-ping, control unit programming dateISO

Specification Desc./QuantityTarget engine revs 1150 rpm (approximate values)Parameter valid at idle, setting depends especially on the en-gine tempera

ELECTRICAL SYSTEMName Torque in NmHorn retainer 15 NmSpeed sensor to front fork retainer 12 NmINSTRUMENT PANEL AND LIGHTSName Torque in NmInstrument p

Devices activation screen pageDEVICES ACTIVATIONThis screen page is used to delete errors in thecontrol unit memory and to activate some systemscontro

Specification Desc./QuantityRight injector Possible short circuit in the earth lead, battery or open circuit.If both injectors do not work, the engine

INDEX OF TOPICSSUSPENSIONS SUSPRevente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

FrontFront forkDiagramKey:1. Left pumping member rod2. Sticker3. Complete cap4. Right sleeve5. Left sleeve6. Upper bushing7. Cap8. Sealing ring9. Snap

15.Right pumping member rod16.Lock nut17.Washer18.Preloading pipe19.Spring20.Lower bushing21.Stem22.Complete cap23.Screw with O-ring24.Sticker25.Pin26

•Unscrew the screws fixing the frontbrake callipers and remove them fromtheir seat.•Support the front part of the vehicle.•Remove the nut fixing the w

•Remove the wheel pin by inserting ascrewdriver in the holes on the pin.•During extraction, support the wheeland then remove it.•Collect the spacer fr

•Remove the fork stem.Draining oilTo drain out the oil follow these operations:• Remove the fork.• Unscrew the complete upper closing cap. Payattentio

• Drain out all the oil inside the stem.• Collect the preload tube.NOTEFOR EASY DRAINAGE OF THE OIL INSIDE THE PUMPINGMEMBER ROD, PRESS THE STEM IN TH

•Remove the locking ring inside thesleeve using a thin screwdriver.CAUTIONBE CAREFUL NOT TO DAMAGE THE SLEEVE RIM.•Slide off the stem from the wheel h

Check clearance between cylinders and pistons on the selected diameter; if it exceeds the value speci-fied, it is necessary to replace cylinders and p

Checking the componentsStemCheck the sliding surface for scorings and/or scratches.These scorings can be eliminated by rubbing them with wet sandpaper

Check that the following components are in goodconditions:•upper bushing;•lower bushing;•pumping member pin.If there are signs of excessive wear or da

•O-Ring on the cap.Reassembling the forkCAUTIONALL COMPONENTS MUST BE CAREFULLY WASHED AND DRIED WITH COMPRESSED AIR BE-FORE REFITTING.•Carry out any

•Screw the bottom screw and tighten itto the prescribed torque.•Insert the cap and the well lubricatedsealing ring in the stem.•Use a suitable inserti

•Fit the dust scraper.Filling oil•Place the sleeve upright in a vice fittedwith protection jaws.•Compress the sleeve in the stem.•Pour part of the for

•Place the cap on the bearing tube, tak-ing care not to damage the O-ring.•Then, tighten the cap to the prescribedtorque.Installing the fork legs•Inse

•Tighten the screws on the fork platesto the prescribed torque.•Remove the wheel pin•Place the right side wheel with spacer.•Insert the pin.•Tighten t

•Insert the sealing washer on the wheelpin.•Tighten the nut fixing the wheel pin tothe prescribed torque•Make sure the stems are aligned mak-ing the f

•Fit the front mud guard.Steering bearingAdjusting play•Remove the top fairing.•Unscrew and remove the screws andmove the instrument panel forward.•Un

•Working on both sides, unscrew andremove the upper plate fixing screw onthe fork stems.•Lift the fork upper plate sliding it off from the stems.•Rive

SERVICE STATIONMANUAL1200 SPORT 4VTHE VALUE OF SERVICEOnly the mechanics of the official Moto Guzzi Service Network know this vehicle well, thanks to

CLEARANCE BETWEEN PISTON RINGS AND SEATS ON PISTONSpecification Desc./QuantityTop ring 0.030 - 0.065 mm (0.00118 - 0.00256 in)Middle ring 0.020 - 0.05

•Using the suitable special tool, set thepreloading of the steering bearings.Specific toolingAP8140190 Tool for steering tighteningSuspensions 1200 SP

INDEX OF TOPICSCHASSIS CHASRevente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

Swinging armRemoving•To remove the swingarm, first removeboth footrest supporting plates and theexhaust silencer.•Slide off the rear brake calliper fr

•Remove the clamp from the dust guardcap.•Loosen the two swingarm terminalscrews.•Unscrew and remove the fixing nut ofthe connecting rod assembly and

•Loosen the ring nut.Specific tooling05.91.26.30 Tool for tightening the swingarmpin ring nut - clutch hub•Helped by a second operator, removethe pin

Installing•Spread a thin layer of lubricatinggrease all along the swingarm pin.•Fit the ring nut in the swingarm pin andscrew it manually.•Working fro

•Fit the dust guard cap in the gearbox.•Lock the dust guard cap with a newclamp.•Place the reaction rod into its seat.•Insert the screw.•Screw the nut

•Place the dust-protection ring betweenthe rim and the cardan shaft takingcare to mount it with the collar facingthe transmission unit.•Place the rear

•Undo and remove the four screws.•Remove the transmission casing slid-ing off the universal joint.CheckingCasing unit removalChassis 1200 SPORT 4VCHAS

Remove the cover (20).Remove the plug (3) to drain out the oil.Lift the cap (10).Remove the clamps (9) and (11).Remove the cap (14).Remove the screws

020676Y Comparator support for piston posi-tion checking•Reset the micrometer on the cylinder rim.•Move the tool so that the micrometer feeler reaches

Collect the ring (15).Remove the screws (7).Remove the casing (4).Remove the clamp (12).Remove the cap (14).Chassis 1200 SPORT 4VCHAS - 210Revente Int

Collect the ring (13).Remove the support unit (8).Casing unit fittingAssemble the dowel pins to the casing with thebuffer and a hammer.Assemble the ca

Heat the casing.Insert the support group in the casing.Assemble the cap and the ring.Fit the cap on the support.Fit the clamp.Chassis 1200 SPORT 4VCHA

Screw the clamp with the specific pliers.Apply the prescribed sealant to the casing.Fit a new sealing ring using the buffer.Lubricate the sealing ring

Fit the casing.Remove the two dowel pins.Assemble the fixing screws (7).Tighten the screws (7) to the prescribed torque.Remove excessive sealant.Assem

Fit the cap with the washer.Screw the cap to the prescribed torque.Fit the breather with the washer.Screw the breather to the prescribed torque.Fill t

Fit the cap in its seat.Wheel axle unitREMOVALRemove the bearing from the wheel axle with asuitable extractor.Turn the unit over.Remove the bearing fr

Assemble the bearings to the wheel axle.Turn the unit over.Assemble the bearings to the wheel axle.Pinion unitREMOVALRemove the stop ring (1) from the

Remove the ring nut (2) and remove the sealingring from the ring nut.NOTETHIS OPERATION DESTROYS THE SEALING RING.Assemble the sealing ring (3) to the

Tighten the ring nut (2) with the special spanner(s4) to the prescribe torque.Insert the stop ring (1) in the ring nut (2) in the in-dicated direction

Product Description Specificationsexceed the requirements of SAE J1703,NHTSA 116 DOT 4, ISO 4925 syntheticfluid specifications.AGIP BRAKE 4 / BRAKE 5.

REMOVALRemove the bushing (1) with a punch.Turn the support (5) over and remove the otherbushing (8).Remove the sealing rings (2) and (7) with a screw

Remove the ball joint (4) with a suitable buffer anda rubber hammer.FITTINGFit the stop ring (6) in the support (5) with suitablepliers.Turn the suppo

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 a

Installing•Insert the transmission casing on theswingarm making sure that the univer-sal joint engages correctly.•Tighten the four screws to the presc

•Place the rear wheel on the swingarm.•Tighten the four screws with theirspacers and the dust-protection ring.•Place the cover.•Place the rear brake c

8. Left clamp9. Expansion chamber10.Rubber ring11.Washer for shafts12.Lambda probe13.Spring14.Gasket15.Clamp16.Silencer17.Screw18.Silencer fixing bush

•Remove the exhaust end.Removing the catalytic converter•Remove the exhaust end and the ex-haust manifolds.•Remove the starter motor protection inorde

Removing the exhaust manifold•Unscrew and remove the two nuts onthe head exhaust stud bolts.•Retrieve the washers.•Loosen the clamp.•Remove the exhaus

•Unscrew and remove the screw andcollect the washer.•Unscrew and remove the nut.•Remove the front tank protection.•Unscrew and remove the oil cooling

•Start the vehicle and let the engine runfor a few minutes so that the oil circu-lates and fills the radiator internalducts.•Stop the engine and check

INDEX OF TOPICSSPECIAL TOOLS S-TOOLSRevente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

INDEX OF TOPICSBRAKING SYSTEMBRAK SYSRevente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

Front brake padsRemoval•Turn the pins and remove both splitpins.•Remove both pins.•Remove the vibration-damping plate.•Extract one pad at a time.CAUTI

Installing•Insert two new pads, placing them sothat the holes are aligned with the cal-liper holes.CAUTIONALWAYS REPLACE BOTH PADS AND MAKE SURE THEYA

Removal•Free the brake pipe and the throttle gripcable from the clamps.•Undo and remove the two screws.•Remove the brake calliper from thedisc.•Turn t

•Extract one pad at a time.CAUTIONAFTER REMOVING THE PADS, DO NOT OPERATE THEBRAKE CONTROL LEVER OR THE CALLIPER PLUNGERSCOULD GO OUT OF THEIR SEATS R

Bleeding the braking systemFrontIf there is air in the hydraulic system, it acts as a bearing, absorbing a large part of the pressure fromthe brake pu

the brake lever and will make it reachthe end of stroke.•Close the bleed valve before the leverreaches its end of stroke.•Repeat the operation until t

tainer. This will release the tension onthe brake lever and will make it reachthe end of stroke.•Close the bleed valve before the leverreaches its end

INDEX OF TOPICSBODYWORK BODYWRevente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

Headlight assy.REMOVAL OF FRONT HEADLIGHT ASSEM-BLY•Working from both sides, unscrew andremove the two lateral screws (1).•Working from both sides, un

SPECIAL TOOLSStores code Description020677Y Alternator belt tensioner, Belt tensioninglever05.91.17.30 Front cover insertion cone020716Y Connecting ro

•Unscrew and remove the rear upperscrew and collect the nut.•Unscrew and remove the front upperscrew.•Remove the air filter housing.•Disconnect the co

•Unscrew and remove the rear upperscrew and collect the nut.•Unscrew and remove the front upperscrew.•Unscrew and remove the screw andremove the left

•Unscrew and remove the two screwsfrom the oil vapour recovery reservoir.•Release the clamp.•Slide off the pipe.•Move the oil vapour recovery reservoi

INDEX OF TOPICSPRE-DELIVERY PRE DERevente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

Carry out the listed checks before delivering the vehicle.WARNINGBE EXTREMELY CAUTIOUS WHEN HANDLING FUEL.Aesthetic inspection- Paintwork- Fitting of

- Through the diagnosis tool, check that the last mapping version is present in the control unit/s and, ifrequired, program the control unit/s again:

- Response to throttle control- Stability when accelerating and braking- Front and rear brake efficiency- Front and rear suspension efficiency- Abnorm

AAir filter: 37BBattery: 49, 54Brake: 231, 232CCentre stand: Clutch: 71, 118, 119, 121, 122, 154Clutch lever: 71DDisplay: 180EEngine oil: 33, 69, 227F

SSpark plug: 31Stand: 72Start-up: 50TTank: 112Transmission: 12, 32Tyres: 14Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf V

Stores code Description05.90.25.30 Gearbox support19.92.96.00 Graduated dial to control ignition timing17.94.75.60 Arrow to control ignition timing12.

Stores code Description14.92.71.00 Tool to fit the sealing ring on the flywheel-side flange12.91.20.00 Tool to fit the flywheel-side flange togeth-er

Stores code Description020676Y Comparator support for piston positionchecking020678Y Tool for clutch rod checking05.91.26.30 Tool for tightening the s

Stores code Description05.90.27.33 Ball joint sealing buffer05.90.27.34 Wrench for pinion ring nut05.90.27.35 Pinion oil seal buffer05.90.27.36 Bevel

INDEX OF TOPICSMAINTENANCE MAINRevente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

SERVICE STATION MANUAL1200 SPORT 4VThis manual provides the main information to carry out regular maintenance operations on your vehicle.This manual i

Maintenance chartNOTECARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VE-HICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS,

Spark plugFor removal:•With a flat screwdriver, remove the Mo-to Guzzi oval symbol.•Undo and remove the fixing screw ofthe spark plug tube protection.

CAUTIONDO NOT ATTEMPT TO READJUST THE ELECTRODE GAP.The electrode gap should be between 0.6 - 0.7mm (0.023 - 0.027 in). Replace the spark plug ifthe g

ReplacementCAUTIONTHE UNIT MUST BE HOT WHEN THE OIL IS CHANGED AS UNDER SUCH CONDITIONS OIL ISFLUID AND THEREFORE EASY TO DRAIN.NOTERIDE SOME km (mile

•Shut off the engine.•Keep the vehicle upright with the twowheels on the ground.•Unscrew and remove the dipstick (1).•Clean the dipstick (1).•Reinsert

•Unscrew and remove the filler plug (1).•Drain the oil into the container; allowseveral minutes for oil to drain out com-pletely.•Check and if necessa

•Shut off the engine.•Keep the vehicle upright with bothwheels on the ground.•Unscrew and remove the cap/dipstick(1) placed on the gearbox right side.

Air filter•Remove the fuel tank.•Disconnect the connector from the airtemperature sensor.•Remove the oil breather pipe.•Unscrew and remove the five sc

ADJUST WITH COLD ENGINE, WITH PISTON AT TOP DEAD CENTRE (TDC) IN COMPRESSIONSTROKE (VALVES CLOSED).•Disconnect both spark plug tubes.•Unscrew and remo

•For the front brake, turn the handlebar fully to the right.•For the rear brake, keep the vehicle upright so that the fluid in the reservoir is at the

Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TOTHE FLUID.WHEN USING A FUNNEL OR ANY OTHER ELEMENT,MAKE SURE IT IS PERFECTLY CLEAN.DO NOT EXCEED THE "

INDEX OF TOPICSELECTRICAL SYSTEM ELE SYSRevente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

Components arrangementKey:1 Coil2 Instrument panel3 Fuel pump4 InjectorElectrical system 1200 SPORT 4VELE SYS - 42Revente Interdite - Revendita Vietat

5 Throttle valve potentiometer6 Fall sensor7 Rear light8 Battery9 Main fuses10 Lambda probe11 Intake air temperature sensor12 Engine revolution sensor

General wiring diagramKey:1. MULTIPLE CONNECTORS2. CLUTCH SWITCH3. MAINTENANCE RELAY4. START-UP RELAYElectrical system 1200 SPORT 4VELE SYS - 44Revent

5. LIGHT RELAY6. RIGHT LIGHT SWITCH7. HAZARD BUTTON8. HORN9. LEFT LIGHT SWITCH10.INSTRUMENT PANEL AIR TEMPERATURE THERMISTOR11.INSTRUMENT PANEL12.KEY

43.LEFT SPARK PLUG44.---45.RIGHT CYLINDER COIL46.LEFT CYLINDER COIL47.RIGHT CYLINDER INJECTOR48.LEFT CYLINDER INJECTOR49.SPEED SENSOR50.Fall sensor51.

DiagnosisChanging the CODEIf you know the code, just enter it and then a new code that will be automatically stored in the memory.If the vehicle is ne

Coil 2 Error DC V DC ECU 24Coil 2 Error DC Gnd ECU 25Injector 1 Error DC V DC ECU 26Injector 1 Error DC Gnd ECU 27Injector 2 Error DC V DC ECU 30Pump

DELETE ERRORSThis option deletes instrument panel errors only, a further confirmation is requested.INSTRUMENT PANEL SOFTWARE UPGRADEThis function is u

INDEX OF TOPICSCHARACTERISTICS CHARSPECIAL TOOLS S-TOOLSMAINTENANCE MAINELECTRICAL SYSTEM ELE SYSENGINE FROM VEHICLE ENG VEENGINE ENGPOWER SUPPLY P SU

Checking the statorSingle-phase generator with regulated voltageMaximum load 40A (550W)Charging voltage 14.2 - 14.8 V (5000 rpm)Start-up system checkp

Lights listFRONT HEADLAMPTail light: 12V - 5WLow-beam light: 12 V - 55 W H7High-beam light: 12 V - 65 W H9REAR LIGHTLEDFusesAUXILIARY FUSESA - Stop, h

MAIN FUSES1 - From battery to voltage regulator (30 A).2 - From battery to key and auxiliary fuses C - D(30 A).NOTETHERE IS ONE SPARE FUSE.Control uni

19 Stepper motor (-)20 5V power supply (NTC sensors)21 Not used22 Not used23 Neutral sensor signal24 Not used25 Engine revolution sensor signal26 Not

17 Power supply from main relay18 Not used19 Not used20 CAN - H line (ccm/instrument panel)21 Not used22 Oxygen probe signal23 Not used24 Vehicle spee

Speed sensorFunctionTo indicate the vehicle speed by reading the frontwheel turning speed.Operation / operating principleHALL effect sensor: a square-

•Check continuity of the cable between PIN 2 of the sensor and PIN 24 of the ECU blueconnector.•Check PIN 24 of the blue connector.•If after all these

Target engine revsExample value:1100 +/- 100 rpmParameter valid at idle, setting depends especially on engine temperature: the ECU unit will try to ke

•PINS A-C: throttle closed approx. 2.5kOhm; throttle open approx. 1.5 kOhm.•PINS A-B: approx. 1.1 kOhmPin-out:•PIN A: ground connection•PIN B: supply

resistance. If resistance is over 2.5 kOhm, it means the red cable is shorted to positive andthe cable harness should be restored•shorted to negative:

INDEX OF TOPICSCHARACTERISTICS CHARRevente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

Specification Desc./Quantity11 Resistance at +60 °C (140 °F) 0.750 kOhm12 Resistance at +70 °C (158 °F) 0.530 kOhm13 Resistance at +80 °C (176 °F) 0.3

error is displayed at the same time, this means that the grey cable common for both sensorsis shorted to positive.•If shorted to negative, check senso

Air temperatureIn case of failure, 25°C is set as temperatureAXONE: ELECTRICAL ERRORSAir temperature sensor P0110 - Open circuit, shorted to positive

Lambda sensorFunctionIn charge of telling the control unit whether themixture is lean or rich.Operation / operating principleThe Marelli injection con

AXONE: STATUSESLambda checkExample value: Open loop / Closed loopClosed loop indicates that the control unit is using the lambda probe signal to keep

PIN 3 of the sensor connector PIN 3 and PIN 11 of the BLUE connector) and restore thecable harness.InjectorFunctionTo supply the correct amount of pet

•Shorted to positive: disconnect the injector connector, take the key to ON and check if thereis voltage on the grey/red cable: if there is voltage, r

tween PIN 37 of the BROWN connector and the component PIN - and restore the cableharness.CoilFunctionIt controls the ignition spark plug in order to g

•If shorted to positive: excessive voltage has been detected at PIN 38 of the BROWN con-nector.•If the circuit is open, shorted to negative: voltage e

continuity, restore the cable harness; if there is cable continuity, with the key set to KEY ON,check the cable ground insulation (from coil connector

RulesSafety rulesCarbon monoxideIf you need to keep the engine running while working on the vehicle, please ensure that you do so inan open or very we

It this error persists, use a pressure gauge to check the pressure of the oil in the enginecircuitNeutral sensorFunctionit tells the gear position to

that the grey/black cable from PIN 1 of the sensor to PIN 23 of the BROWN connector isshorted to ground: restore the cable harness.Clutch lever sensor

the sensor. If the circuit is open, it means that the yellow/purple cable from PIN 1 of thesensor to PIN 33 of the BLUE connector is shorted to ground

Bank angle sensorFunctionit tells the vehicle position to the control unit.Operation / operating principleWhen the sensor is inverted, the circuit is

Air temperature sensor - instrument panelFunctionIt tells the ambient air temperature to the instru-ment panel.Operation / operating principleNTC type

If a short circuit to ground is detected at PIN 9 of the instrument panel connector, the display will showa full scale air temperature indication of 6

Example value:Run/StopDIAGNOSIS•Indication on Axone always STOP: disconnect the connector and, with the switch set toRUN, check if there is continuity

15 ANTITHEFT DEVICE LED (IF CONNECTED)16 SELECT 317 SENSORS EARTH CONNECTION18 GENERAL EARTH CONNECTION19 GENERAL EARTH CONNECTION20 GENERAL EARTH CON

INDEX OF TOPICSENGINE FROM VEHICLE ENG VERevente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

Vehicle preparationBefore removing the engine block, proceed as follows:•From the back, secure the vehicle with belts attached to a hoist.•From the fr

BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAINTED SURFACES.WHEN SERVICING THE BRAKING SYSTEM OR THE CLUTCH SYSTEM PROTECT THESE COM-PON

•Disconnect the engine temperaturesensor connector•Disconnect the revolution sensor con-nector.•Disconnect the alternator connectors.•Disconnect the n

•Unscrew and remove the stud bolt.•Disconnect the ground leads.•Disconnect the starter motor connec-tors.•Unscrew and remove the three screwsand remov

•Unscrew and remove the nut.•Remove the front tank protection.•Disconnect the stand sensor connec-tor and release it from the clamps.•Unscrew and remo

•Working from both sides, unscrew andremove the three inlet manifoldscrews.•Collect the gasket.•Remove both footrest holding plates.•Unscrew and remov

•Unscrew and remove the upper nut fix-ing the engine and collect the washer.•Remove the upper pin and collect thewasher.•Lower the engine completely.•

•Working on both sides, insert thewasher and screw the screw withouttighten it.•Working on both sides, place the plates•Working from the left side, fi

•Working from both sides, place the in-let manifold fitting a new gasket be-tween the manifold and head.•Fasten the inlet manifold with the threescrew

•Place the front tank protection.•Screw the nut.•Fit the gearbox oil breather pipe.•Fit the clutch control cylinder.•Tighten the three screws.•Connect

•Connect the ground leads and tightenthe stud bolt.•Connect the neutral sensor connector.•Connect the alternator connectors.•Connect the revolution se

•Connect the engine temperature sen-sor connector.•Connect and adjust the throttle grip ca-ble clearance.•Place the swingarm with cardan shaftand the

•Keep mated parts together since they have "adjusted" to each other due to normal wear.•Some components must be used together or replaced al

INDEX OF TOPICSENGINE ENGRevente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

GearboxDiagramKey:1. Ball bearing1200 SPORT 4V EngineENG - 91Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

2. Circlip3. Thickness4. Pin5. Complete desmodromic6. Ball bearing7. Spring8. Spacer9. Circlip10.Fifth wheel11.Linking pin12.Gear13.Circlip14.Thrust w

40.Index lever41.Spring42.Ball bearing43.Gear44.Gear45.Ball bearing cage46.Thrust washer47.Circlip48.Gear49.Circlip50.Gear51.Main shaft52.Transmission

•Unscrew and remove the gearbox oilfiller cap.•Place a container of suitable capacityunder it, unscrew and remove the capand then bleed all gearbox oi

•Undo and remove the two screws.•Undo and remove the screw.•Remove the gearbox.See alsoRemoving the starter motorReplacementGearbox shafts1200 SPORT 4

Disassembling the gearbox•Remove the gearbox.•Unscrew and slide off the odometergear and collect the abutment washerthat is inside the gearbox.•From t

•Slide off the rod with the two bushings.•Undo and remove the five externalscrews.•Place the gearbox on the specific gearbox support tool and on a vic

•Remove the bearings from the gearboxif necessary.•Release the spring.•Pressing the selector, slide off the whole transmission lever.•Use rubber bands

•Remove the forks and collect the shaft.1200 SPORT 4V EngineENG - 99Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten