MOTO GUZZI NORGE 1200 Bedienungsanleitung

SERVICE STATION MANUAL

854326

Norge 1200

SERVICE STATION

MANUAL

Norge 1200

While the basic features as described and illustrated in this manual remain unchanged, Moto Guzzi

s.p.a. reserves the right to introduce changes to their own models at any time. All rights regarding

electronic data storage, total or partial reproduction or adaptation of this manual by any means are

reservedforallCountries.Thirdpartyproductsorservicesreferredtointhismanualshouldbeconsidered

onlyinformative andare notbinding. MotoGuzzi s.p.a.shall notbe liablefor anyfunctions oruse ofthese

products.

Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

SERVICE STATION MANUAL

Norge 1200

This manual provides the main information to carry out regular maintenance operations on your scooter.

This manual is intended to Moto Guzzi Dealers and their qualified mechanics; several concepts have

been deliberately omitted as they are considered unnecessary. As it is not possible to include complete

mechanical notions in this manual, users should have basic mechanical knowledge or minimum

knowledge about the procedures involved when repairing scooters. 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 Sectionsmarkedwith thissymbol indicatethe correctuseof thevehicle

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

INDEX OF TOPICS

CHARACTERISTICS CHAR

Rules

Safety rules

Carbon monoxide

If you need to keep the engine running in order to carry out any procedure, please ensure that you do

so in an open or very well ventilated area. Never let the engine run in an enclosed area. If you do work

in an enclosed area, make sure to use a smoke-extraction system.

CAUTION

EXHAUSTEMISSIONSCONTAINCARBONMONOXIDE,APOISONOUS GASWHICHCANCAUSE

LOSS OF CONSCIOUSNESS AND EVEN DEATH.

Fuel

CAUTION

FUEL USED TO POWER INTERNAL COMBUSTION ENGINES IS HIGHLY FLAMMABLE AND CAN

BECOME EXPLOSIVE UNDER SPECIFIC CONDITIONS. IT IS THEREFORE RECOMMENDED TO

CARRY OUT REFUELLING AND MAINTENANCE PROCEDURES IN A VENTILATED AREA WITH

THE ENGINE SHUT OFF. DO NOT SMOKE DURING REFUELLING AND NEAR FUEL VAPOURS,

AVOID ANY CONTACT WITH NAKED FLAMES, SPARKS OR OTHER SOURCES WHICH MAY

CAUSE THEM TO IGNITE OR EXPLODE.

DO NOT DISPOSE OF FUEL INTO THE ENVIRONMENT.

KEEP OUT OF THE REACH OF CHILDREN

Hot components

The engine and the exhaust system components get very hot and remain in this condition for a certain

time interval after the engine has been shut off. Before handling these components, make sure that you

are wearing 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 LATEX GLOVES WHEN SERVICING THE VEHICLE.

ENGINE OR TRANSMISSION 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 INTO THE ENVIRONMENT

KEEP OUT OF THE REACH OF CHILDREN

Brake and clutch fluid

Characteristics Norge 1200

CHAR - 2

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

WHEN SERVICING THE BRAKING OR THE CLUTCH SYSTEM PROTECT THESE COMPONENTS

WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THE SYS-

TEMS. BRAKE AND CLUTCH FLUIDS ARE EXTREMELY HARMFUL FOR YOUR EYES. IN THE

EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THEM IMMEDIATELY WITH ABUN-

DANT COLD, CLEAN WATER AND SEEK MEDICAL ADVICE IMMEDIATELY.

KEEP OUT OF THE REACH OF CHILDREN

Battery electrolyte and hydrogen gas

CAUTION

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

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

TROLYTE, WEAR TIGHT-FITTING GLOVES AND PROTECTIVE APPAREL. IF THE ELECTRO-

LYTIC FLUID COMES INTO CONTACT WITH THE SKIN, RINSE WELL WITH ABUNDANT FRESH

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

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

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

AN EYE SPECIALIST IMMEDIATELY. IF THE FLUID IS ACCIDENTALLY SWALLOWED, DRINK

LARGE QUANTITIES OF WATER OR MILK, FOLLOWED BY MILK OF MAGNESIA OR VEGETA-

BLE OIL AND SEEK MEDICAL ADVICE IMMEDIATELY. THE BATTERY RELEASES EXPLOSIVE

GASES; KEEP IT AWAY FROM FLAMES, SPARKS, CIGARETTES OR ANY OTHER HEAT

SOURCE. ENSURE ADEQUATE VENTILATION WHEN SERVICING OR RECHARGING THE BAT-

TERY.

KEEP OUT OF THE REACH OF CHILDREN

BATTERY LIQUID IS CORROSIVE. DO NOT POUR 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 DISASSEMBLING COMPONENTS

•Beforedismantlingcomponents, removedirt, mud,dust and foreignbodies fromthe 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 other tools other than the

especially designed wrench.

•Mark positions on all connection joints (pipes, cables, etc.) before separating them, and

identify them with distinctive symbols.

•Each component needs to be clearly marked in order to be identified during assembly.

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

Norge 1200 Characteristics

CHAR - 3

•Keep coupled parts together since they have "adjusted" to each other due to normal wear

and tear.

•Some components must be used together or replaced altogether.

•Keep away from heat sources.

REASSEMBLING COMPONENTS

CAUTION

BEARINGS MUST BE ABLE TO ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTH-

ERWISE THEY NEED REPLACING.

•Only use ORIGINAL Moto Guzzi SPARE PARTS.

•Comply with lubricant and consumables usage 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 ap-

plying the tightening torque.

•Always replace self-locking nuts, washers, sealing rings, circlips, O-rings, split pins and

screws with new ones if their tread is damaged.

•When fitting bearings, make sure to lubricate them well.

•Check that each component is fitted correctly.

•After a repair or routine maintenance procedure, carry out pre-ride checks and test the ve-

hicle on private grounds or in an area with low traffic density.

•Clean all junction surfaces, oil guard rims and washers before refitting them. Smear a light

layer of lithium-based grease on the oil guard rims. Reassemble the oil guard and the bear-

ings with the brand or lot number facing outward (visible side).

ELECTRIC CONNECTORS

Electric connectors must be disconnected as described below as non-compliance with the procedure

so described 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.

•Ifthere aresigns ofdirt, rust,humidity, etc.,clean theconnector internalparts carefullyusing

a pressurised air jet.

•Make sure that the cables are correctly linked to the connector internal terminal ends.

•Then insert the two connectors making sure that they couple correctly (if the relevant hooks

are provided, 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 TORQUE

CAUTION

Characteristics Norge 1200

CHAR - 4

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