SERVICE STATION MANUAL

854331

GRISO 1100
 SERVICE STATION
MANUAL

GRISO 1100

While the basic features as described and illustrated in this manual remain unchanged, Moto Guzzi
s.p.a. reserves the right to introduce changes to their own models at any time. All rights regarding
electronic data storage, total or partial reproduction or adaptation of this manual by any means are
reserved for all Countries. Third party products or services referred to in this manual should be considered
only informative and are not binding. Moto Guzzi s.p.a. shall not be liable for any functions or use of these
products.
 SERVICE STATION MANUAL
GRISO 1100
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
GRISO 1100 Characteristics

Rules

Safety rules

Carbon monoxide
If you need to keep the engine running while working on the vehicle, please ensure that you do so in
an open or very well ventilated area. Never 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 VA-
POURS, 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 VE-

HICLE.
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

CHAR - 7
Characteristics GRISO 1100

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 given below
carefully.

BEFORE DISASSEMBLING 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 positions on all connection joints (pipes, cables etc.) before separating them, and
identify them with 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.

CHAR - 8
GRISO 1100 Characteristics

• Some components must be used together or replaced completely.

• Keep away from heat sources.

REASSEMBLING COMPONENTS
CAUTION
BEARINGS MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE, THEY
NEED TO BE REPLACED.
• Only use ORIGINAL Moto Guzzi SPARE PARTS.
• Comply with lubricant and consumables use guidelines.
• 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 (OR), split 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 ve-
hicle 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).

ELECTRICAL CONNECTORS
Electric connectors must be disconnected as described below; failure to comply with this procedure
causes irreparable damage to both the connector and the wiring harness:
Press the relative safety clips, if applicable.
• 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
DO NOT DISCONNECT CONNECTORS BY PULLING THE CABLES.
NOTE
THE TWO CONNECTORS CAN ONLY BE CONNECTED IN ONE DIRECTION: CONNECT THEM
THE RIGHT WAY ROUND.
TIGHTENING TORQUES
CAUTION
REMEMBER THAT THE TIGHTENING TORQUES FOR ALL FASTENING ELEMENTS ON WHEELS,
BRAKES, WHEEL AXLES AND ANY OTHER SUSPENSION COMPONENTS PLAY A KEY ROLE
IN ENSURING VEHICLE SAFETY AND MUST COMPLY WITH SPECIFIED VALUES. CHECK THE

CHAR - 9
Characteristics GRISO 1100

TIGHTENING TORQUES OF FASTENING ELEMENTS ON A REGULAR BASIS AND ALWAYS USE

A TORQUE WRENCH TO REASSEMBLE THESE COMPONENTS. FAILURE TO COMPLY WITH
THESE RECOMMENDATIONS MAY CAUSE ONE OF THESE COMPONENTS TO LOOSEN OR
EVEN DETACH, CAUSING A WHEEL TO LOCK OR COMPROMISING VEHICLE HANDLING. THIS
MAY LEAD TO FALLS, WITH THE RISK OF SERIOUS INJURY OR DEATH.

Running-in

Running the engine in correctly is essential for ensuring engine longevity and functionality. Twisty roads
and gradients are ideal for running in the engine, brakes and suspension effectively. Vary your riding
speed during the running in period. This ensures that components operate in "loaded" conditions and
then "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 the guidelines detailed below:
• Do not fully open the throttle grip abruptly at low engine speeds, either during or after the
running in period.
• 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.
• Between 1000 km (625 miles) and 2000 km (1250 miles) travelled, ride more vigourously,
vary speeds and twist throttle fully for some short periods for best coupling of the compo-
nents; do not exceed 6000 rpm.
• After 2000 km (1250 miles) a better engine performance may be expected, but without ex-
ceeding the engine maximum rpm allowed (7600 rpm).

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.

CHAR - 10
GRISO 1100 Characteristics

This number is composed by numbers and letters,

as in the example shown below.
ZGULS0000YMXXXXXX
KEY:
ZGU: WMI (World manufacturer identifier) code;
LS: model;
000: 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 2,260 mm (89.0 in)
Width 880 mm (34.6 in)
Maximum height 1070 mm (42.1 in)
Saddle height 800 mm (31.5 in)
Minimum earth clearance 185 mm (7.3 in)
Wheelbase 1554 mm (61.2 in)
Kerb weight 240 kg (529 lb)

Engine

ENGINE
Specification Desc./Quantity
Type traverse-mounted twin-cylinder four-stroke V 90°
No. of cylinders 2
Cylinder arrangement V 90°
Total engine capacity 1064 cm3 (65 cu in)
Bore / stroke 92 x 80 mm (3.6 x 3.1 in)

CHAR - 11
Characteristics GRISO 1100

Specification Desc./Quantity
Compression ratio 9.8 :1
Electric starter
Engine idle speed 1100 ± 100 rpm
Clutch dry, twin disc with hydraulic control
Lubrication Pressure-fed, controlled by valves and trochoidal pump
Air filter cartridge-type dry filter
Cooling air
Fuel system Electronic injection (Weber . Marelli) with stepper motor
Diffuser Ø 45 mm (1.77 in)
Fuel Premium unleaded petrol, minimum octane rating 95 (NORM)
and 85 (NOMM)
Timing system diagram: 2 rod valves and rocking levers
Valid values with checking clearance between rocking levers inlet: 0.10 mm (0.0039 in)
and valve outlet: 0.15 mm (0.0059 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
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 U-joint
Ratio 12/44 = 1:3.6667

Capacities

CAPACITY
Specification Desc./Quantity
Engine oil Oil and oil filter change 3600 cm³ (219 cu.in)
Gearbox oil 500 cm³ (30.5 cu.in)
Transmission oil 380 cm³ (23.2 cu.in)
Fuel (reserve included) 17.2 l (4.6 gal)
Fuel reserve 3.3 l (0.87 gal)
Fork oil 520 ± 2.5 cm³ (31.7 ± 0.15 in) (for each stem)
Seats 2
Vehicle maximum load 210 kg (463 lb) (rider + passenger + luggage)

Electrical system

ELECTRICAL SYSTEM
Specification Desc./Quantity
Inner spark plug (long life) (only for 1100 models) NGK PMR8B
Outer spark plug NGK BPR6ES
Electrode gap 0.6 - 0.7 mm (0.024 - 0.028 in)
Battery 12 V - 18 Ampere/hour
Alternator (permanent magnet type) 12 V - 550 W
Main fuses 30 A
Auxiliary fuses 3A - 15A - 20A
Daylight running light 12V - 5 W
Low/High beam headlight (halogen) 12 V - 55 W / 60 W H4
Turn indicators 12V - 10 W

CHAR - 12
GRISO 1100 Characteristics

Specification Desc./Quantity
Rear daylight running light/stop light LED
Dashboard lighting LED
License plate light 12V - 5 W
Turn indicator warning light LED
Neutral gear warning light LED
Alarm-shift warning light LED
Side stand down warning light LED
Low fuel warning light LED
High beam warning light LED
Oil pressure warning light LED

Frame and suspensions

CHASSIS
Specification Desc./Quantity
Type Double cradle, high strength steel tube chassis
Trail 108 mm (4.25 in)
Headstock angle 26° 30'
Front: Hydraulic telescopic fork, Ø 43 mm (1.69 in), adjustable in
spring preloading, hydraulic rebound and compression damp-
ing.
Wheel travel 120 mm (4.72 in)
Rear single arm with progressive linkage, single shock absorber with
spring preload, hydraulic compression and rebound damping
adjustment.
Wheel travel 110 mm (4.33 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

CHAR - 13
Characteristics GRISO 1100

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 Rennsport;
MICHELIN Pilot Power;
DUNLOP D208 RR
PIRELLI Diablo Corsa;
Front 120/70 - ZR 17" 58 W
Inflation pressure (front) 2.3 bar (230 kPa) (33.4 PSI)
Inflation pressure with passenger (front) 2.3 bar (230 kPa) (33.4 PSI)
Rear 180/55 - ZR 17" 73 W
Inflation pressure (rear) 2.5 bar (250 kPa) (36.3 PSI)
Inflation pressure with passenger (rear) 2.7 bar (270 kPa) (39.1 PSI)

Tightening Torques

HEADS
Name Torque in Nm
Oil cap (2) 25 Nm (18.44 lbf ft)
Exhaust system stud bolt (4) 10 Nm (7.38 lbf ft) - Loctite 648
Rocking lever support nut - M10x1.5 (8) 15 Nm (11.06 lbf ft) + 90º + 90º
Rocking lever nut (4) 10 Nm (7.38 lbf ft)
Set screw - TE M6x16 (4) 10 Nm (7.38 lbf ft)
Head cover screw - M6x25 (16) 10 Nm (7.38 lbf ft)
Head fixing screw (4) 15 Nm (11.06 lbf ft) + 90º
Oil temperature sensor 11 Nm (8.11 lbf ft) - Loctite 243
Oil temperature sensor container 11 Nm (8.11 lbf ft) - Loctite 601
Outer Spark plugs 30 Nm (22.13 lbf ft) - Molikote
Inner spark plugs 15 Nm (11.06 lbf ft) - Molikote

CRANKCASE
Name Torque in Nm
Crankcase stud bolt - cylinder (8) 25 Nm (18.44 lbf ft)
Transmission side flange stud bolt - M8x66 (3) 35 Nm (25.81 lbf ft)
Transmission side flange stud bolt - M8x75 (2) 35 Nm (25.81 lbf ft)
Crankshaft flange screw - TE M8x25 (14) 25 Nm (18.44 lbf ft)
Timing system cover screw - TCEI M8x55 (4) 25 Nm (18.44 lbf ft)
Timing system cover screw - TCEI M6x30 (10) 10 Nm (7.38 lbf ft)
Oil vapour union screw - TCEI M6x20 (2) 10 Nm (7.38 lbf ft)
Timing system outer cover screw - TCEI M6x16 (4) 10 Nm (7.38 lbf ft)
Screw TSPEI M4x8 (2) 5 Nm (3.69 lbf ft) - Loctite 243
TCEI M6x40 Screw (2) 10 Nm (7.38 lbf ft)
Timing sensor - TCEI M5x12 (2) 6 Nm (4.42 lbf ft)
Crankcase stud bolts - chassis (4) 40 Nm (29.5 lbf ft) - Loctite 601

OIL SUMP
Name Torque in Nm
Oil radiator pipe fitting on sump (2) 20 Nm (14.75 lbf ft)
Oil pipe on sump 20 Nm (14.75 lbf ft)
Oil sump lower screw - TCEI M6x30 (4) 10 Nm (7.38 lbf ft)
Oil sump screw - TCEI M6x55 (14) 10 Nm (7.38 lbf ft)
Oil sump screw - TCEI M6x60 (2) 10 Nm (7.38 lbf ft)
Oil drainage plug - M10x1 (1) 20 Nm (14.75 lbf ft)
Oil filter (1) 15 Nm (11.06 lbf ft)
Oil filter fitting (1) 40 Nm (29.5 lbf ft) - Loctite 243
Oil pipe in sump 20 Nm (14.75 lbf ft) - Loctite 648
Thermostat cap 40 Nm (29.5 lbf ft)

CHAR - 14
GRISO 1100 Characteristics

Name Torque in Nm
Pressure-relief plug 40 Nm (29.5 lbf ft)
Oil intake filter fixing screw - TCEI M6x16 (1) 10 Nm (7.38 lbf ft) - Loctite 648

OIL PUMP
Name Torque in Nm
Oil pump fixing screw - TBEI M6x30 (3) 10 Nm (7.38 lbf ft) - Loctite 243
Oil pump gear nut - M10x1.25 (1) 20 Nm (14.75 lbf ft)
Oil delivery pipe screw (1) 17 Nm (12.54 lbf ft)
Oil pressure sensor 45 Nm (33.19 lbf ft)

TIMING SYSTEM
Name Torque in Nm
Camshaft flange screw - TE M6x20 (3) 10 Nm (7.38 lbf ft)
Timing system gear nut on camshaft - M18 (1) 150 Nm (110.63 lbf ft)
Timing system gear nut on crankshaft - M25 (1) 120 Nm (88.51 lbf ft)
Camshaft support screw on timing system cover - TCEI M4x10 5 Nm (3.69 lbf ft) - Loctite 243
(4)
Belt tension 50 Nm (36.88 lb ft)

GENERATOR
Name Torque in Nm
Alternator fixing screw - TCEI M8x45 (1) 22 Nm (16.23 lbf ft)
Alternator fixing nut - M10x1.5 (1) 30 Nm (22.13 lbf ft)
Alternator pulley nut on crankshaft - M16 (1) 80 Nm (59 lbf ft) - Loctite 243

CRANKSHAFT - FLYWHEEL
Name Torque in Nm
Start-up crown fixing screw on flywheel (8) 18 Nm (13.28 lbf ft) - Loctite 243
Connecting rod screw (4) - pre-tightening 40 Nm (29.5 lbf ft)
Connecting rod screw (4) - final tightening 80 Nm (59 lbf ft)
Flywheel fixing screw on crankshaft - M8x25 (6) 42 Nm (30.98 lbf ft) - Loctite 243

GEAR
Name Torque in Nm
Gear shift cable lever nut 10 Nm (7.38 lbf ft)
Gear shift tie rod lever nut on gear pre-selector 10 Nm (7.38 lbf ft)
Gearbox to crankcase fixing nut - M8 (5) 20 Nm (14.75 lbf ft)
TE flanged screw fixing gearbox to crankcase - M8x45 (1) 20 Nm (14.75 lbf ft)
Oil cap M18x1.5 (1) 28 Nm (20.65 lbf ft)
Breather cap (1) 8 Nm (5.9 lbf ft)
Gear in neutral sensor (1) 10 Nm (7.38 lbf ft)
Oil drainage plug - M10x1 (1) 24 Nm (17.7 lbf ft)
Transmission shaft ring nut (1) 100 Nm (73.76 lbf ft)

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

CHASSIS
Name Torque in Nm
Front engine to chassis retainer 80 Nm
Transmission to chassis retainer (M12x250 + M12x230) 50 Nm
Right fixing plate - transmission retainer 25 Nm

CHAR - 15
Characteristics GRISO 1100

Name Torque in Nm
Plate clamp - Blow-by retainer 10 Nm
Coil plate retainer 10 Nm
Electronic control unit retainer 10 Nm
Bushings to electronic control unit retainer 10 Nm
Retainer for tank to chassis rear support rubber rings Manual
Filter casing fixing bolts 10 Nm
Left and right footrest plate to chassis upper retainer 25 Nm
Left and right footrest plate to chassis lower retainer 18 Nm
Brake switch on plate retainer Manual
Plate ring to plate retainer 6 Nm
Retainer for cable guide on right footrest plate 6 Nm

FOOTRESTS AND LEVERS

Name Torque in Nm
Footrest rubber retainer 10 Nm
Rider footrest sliding pin - M8 25 Nm
Passenger footrest support to lateral plates retainer 38 Nm
Rider heelrest to plates retainer 6 Nm
Passenger heelrest retainer 3 Nm
Rod retainer (nut) 10 Nm
Gear shift lever / brake pin retainer 10 Nm
Gear shift lever / pre-selector retainer 10 Nm
Gear shift lever - brake pin retainer 15 Nm

SIDE STAND
Name Torque in Nm
Stand plate to engine upper retainer 50 Nm
Stand plate to engine lower retainer 25 Nm
Side stand retainer pin 10 Nm
Switch fixing screw 10 Nm
Lock nut 30 Nm
Stand cable guide to engine retainer 50 Nm
Lateral lever arm retainer 10 Nm

SWINGARM
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
Tube lock plate to steering base retainer 6 Nm
Fork stem on upper plate retainer 18 Nm
Upper and lower screws fixing fork stem on lower plate 22 Nm
Central screw fixing fork stem on lower plate 20 Nm
Headstock ring nut 40 Nm
Headstock counter ring nut manual + 90 degrees
Upper yoke fixing cap 100 Nm
Fork hubs closing 25 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

CHAR - 16
GRISO 1100 Characteristics

AIR FILTER CASING

Name Torque in Nm
Blow-by expansion tank spacer to engine retainer 10 Nm
Blow-by expansion tank to spacer retainer 10 Nm
Filter housing to chassis retainer 10 Nm

EXHAUST
Name Torque in Nm
Exhaust pipe to engine retainer 25 Nm
Silencer to chassis connecting pipe retainer 25 Nm
Silencer to footrest support retainer 25 Nm
Protection to connecting pipe retainer 10 Nm
Lambda probe retainer 38 Nm
Clamp retainer 10 Nm

FRONT WHEEL
Name Torque in Nm
Wheel pin nut 80 Nm
Disc retainer 30 Nm

REAR WHEEL
Name Torque in Nm
Disc retainer 25 Nm
Rear wheel retainer 10.9 110 Nm

FRONT BRAKING SYSTEM

Name Torque in Nm
Front brake right and left calliper retainer 50 Nm

REAR BRAKING SYSTEM

Name Torque in Nm
Rear brake calliper retainer 50 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 pump retainer 10 Nm

HANDLEBAR AND CONTROLS

Name Torque in Nm
Retainer for handlebar lower U-bolts on steering upper plate 50 Nm
Retainer for handlebar upper U-bolts 25 Nm
Anti-vibration counterweight fastener 10 Nm
Brake pump and clutch U-bolts retainer 10 Nm
Right and left light switch retainer 1.5 Nm
Clutch control cylinder to gear retainer 10 Nm
Rear-view mirror Manual

ELECTRICAL SYSTEM
Name Torque in Nm
Coil retainer 2 Nm
Horn retainer 15 Nm
Odometer sensor on bevel gear pair retainer 3 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 10 Nm
Instrument panel retainer 3 Nm
Light support to fork lower plate retainer 25 Nm

CHAR - 17
Characteristics GRISO 1100

Name Torque in Nm
Retainer for front and rear arrows 10 Nm
Headlamp retainer 15 Nm
Rear light to tail clamp retainer 3 Nm

FUEL PUMP FLANGE

Name Torque in Nm
Pump support to tank retainer 6 Nm
Tank breather joint 6 Nm

FUEL TANK
Name Torque in Nm
Filler to tank retainer 5 Nm
Cap ring nut to tank retainer 5 Nm
Screws on cap ring nut (aesthetic) 5 Nm
Tank to chassis front retainer 10 Nm
Battery housing and tank to chassis rear retainer 6 Nm

CHASSIS / FAIRINGS (FRONT)

Name Torque in Nm
Front mudguard retainer 6 Nm
Control unit protection retainer 6 Nm
Deflectors to chassis front upper retainer Manual
Deflectors to chassis front lower retainer Manual
Deflectors to chassis rear retainer Manual
Retainer fixing the deflectors to deflector clamp Manual

CHASSIS/ FAIRINGS (REAR)

Name Torque in Nm
Retroreflector to support retainer 4 Nm
Retroreflector support to license plate holder retainer 4 Nm
License plate holder and light support retainer 4 Nm
License plate holder to lower clamp retainer manual
Tail section to chassis lower clamp retainer 25 Nm
Fuse bracket and relay support retainer 4 Nm

FINISHINGS
Name Torque in Nm
Ignition lock retainer - shear head screw - 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 the clearance between the cylinders and pistons; 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 (0.0033 lb) is admitted.

ADMITTED MEASUREMENTS
Specification Desc./Quantity
cylinder diameter 92.000 - 92.020 mm (3.62204 - 3.62282 in)

CHAR - 18
GRISO 1100 Characteristics

Specification Desc./Quantity
piston diameter 91.947 - 91.967 mm (3.61995 - 3.62074 in)
fitting clearance 0.048 - 0.068 mm (0.00189 - 0.00268 in)

Piston rings

Check the sealing piston rings and the oil scraper.

On each piston there are:
1 top piston ring;
1 middle stepped piston ring;
1 oil scraper piston ring.
The ends of the fitted piston rings are out of phase.
Fitting backlash detected between the ring thickness and seats on the piston:
Sealing rings and oil scraper 0.030 - 0.065 mm (0.00118 - 0.00256 in)
Gap between the end of the piston rings inserted in the cylinder:
Upper sealing ring and stepped ring 0.40 - 0.65 mm (0.00158 - 0.00255 in)
Oil scraper ring 0.30 - 0.60 mm (0.00118 - 0.00236 in).
Turn the rings so that the coupling ends are 120 degrees from each other.

Crankcase - crankshaft - connecting rod

CAMSHAFT (CAM) SUPPORT DIAMETER AND THEIR SEATS ON THE CRANKCASE

(TIMING SYSTEM SIDE)
Specification Desc./Quantity
Shaft support diameter 47.000 - 46.984 mm

CHAR - 19
Characteristics GRISO 1100

Specification Desc./Quantity
(1.85039 ÷ 1.84976 inch)
Seat diameter on base 47.025 - 47.050 mm
(1.85137 ÷ 1.85236 inch )
fitting clearance 0.025 - 0.066 mm
(0.00098 ÷ 0.00260 inch)

CAMSHAFT (CAM) SUPPORT DIAMETER AND THEIR SEATS ON THE CRANKCASE

(FLYWHEEL SIDE)
Specification Desc./Quantity
Shaft support diameter 32.000 - 31.984 mm
(1.25984 ÷ 1.25921 inch)
Seat diameter on base 32.025 - 32.050 mm
(1.26082 ÷ 1.26181 inch)
fitting clearance 0.025 - 0.066 mm
(0.00098 ÷ 0.00260 inch)

TAPPET-SEAT COUPLING ON CRANKCASE DATA (PRODUCTION)

Specification Desc./Quantity
Seats diameter 22.021 - 22.000 mm
(0.86697 ÷ 0.86614 inch)
Tappet external diameter 21.996 - 21.978 mm
(0.86598 ÷ 0.86527 inch)
Fitting clearances 0.004 - 0.043 mm
(0.00016 ÷ 0.00169 in.)

Recommended products chart

RECOMMENDED PRODUCTS
Product Description Specifications
AGIP RACING 4T 10W-60 Engine oil SAE 10W - 60. As an alternative to rec-
ommended fluids, use top branded oils
with performances that meet or exceed
the requirements of CCMC G-4 API. SG
specifications.
AGIP GEAR SAE 80 W 90 Transmission oil -
AGIP GEAR MG/S SAE 85 W 90 Gearbox oil -
AGIP FORK 7.5W Fork oil SAE 5W / SAE 20W
AGIP GREASE SM2 Lithium grease with molybdenum for NLGI 2
bearings and other points needing lubri-
cation
Neutral grease or petroleum jelly. Battery poles
AGIP BRAKE 4 / BRAKE 5.1 Brake fluid As an alternative for recommended flu-
ids, use top branded fluids that meet or
exceed the requirements of SAE J1703,
NHTSA 116 DOT 4, ISO 4925 synthetic
fluid specifications.
AGIP BRAKE 4 / BRAKE 5.1 Clutch fluid As an alternative for recommended flu-
ids, use top branded fluids that meet or
exceed the requirements of SAE J1703,
NHTSA 116 DOT 4, ISO 4925 synthetic
fluid specifications.
NOTE
USE ONLY NEW BRAKE FLUID. DO NOT MIX DIFFERENT BRANDS OR TYPES OF OIL WITHOUT
CHECKING THEIR BASE COMPATIBILITY.

CHAR - 20
INDEX OF TOPICS

SPECIAL TOOLS S-TOOLS

Special tools GRISO 1100

SPECIAL TOOLS
Stores code Description
06.94.86.00 belt tensioning tool

05.91.17.30 Front cover insertion cone

05.91.25.30 Gearbox opening

05.90.19.30 Inner spark plug removal

05.92.80.30 Piston ring clamp

05.92.72.30 Timing system cover sealing ring punch

S-TOOLS - 22
GRISO 1100 Special tools

Stores code Description

01.92.91.00 Wrench for removing the cover on sump
and filter

05.90.25.30 Gearbox support

19.92.96.00 Graduated dial to control ignition timing

17.94.75.60 Arrow to control ignition timing

12.91.18.01 Tool to lock the flywheel and the starting

ring gear

12.91.36.00 Tool to remove the flywheel-side flange

10.90.72.00 Tool for valve removal and refitting

S-TOOLS - 23
Special tools GRISO 1100

Stores code Description

30.90.65.10 Tool for clutch fitting

14.92.71.00 Tool to fit the sealing ring on the flywheel-

side flange

12.91.20.00 Tool to fit the flywheel-side flange togeth-

er with seal ring on the crankshaft

19.92.71.00 Tool to fit the seal ring on the flywheel-

side flange

14.92.73.00 Tool for camshaft gear sealing

981006 Graduated dial hub

AP8140190 Tool for steering tightening

S-TOOLS - 24
GRISO 1100 Special tools

Stores code Description

000019663300 Tool for clutch shaft removal

30.91.28.10 Clutch body locking

05.90.27.30 Gearbox support

05.90.27.31 Gearbox oil seal buffer

05.90.27.32 Buffer handgrip

05.90.27.33 Ball joint sealing buffer

05.90.27.34 Wrench for pinion ring nut

S-TOOLS - 25
Special tools GRISO 1100

Stores code Description

05.90.27.35 Pinion oil seal buffer

05.90.27.36 Bevel gear pair support

AP8140145 fitting tool for Ø 41 mm seal rings

AP8140146 Weight

AP8140147 Spacer tool

AP8140148 Spacer-piston separating plate

AP8140149 Protection for fitting operations

S-TOOLS - 26
GRISO 1100 Special tools

Stores code Description

AP8140150 Perforated rod for piston air bleed

AP8140151 Complete tool kit for fork

GU14912603 Hook spanner for fixing ring nut of the
clutch shaft internal body

S-TOOLS - 27
INDEX OF TOPICS

MAINTENANCE MAIN
GRISO 1100 Maintenance

Maintenance chart
NOTE
CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VE-
HICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS, OFF ROAD OR FOR TRACK
USE.

AT EVERY START-UP
Action
Engine oil pressure warning light - check and clean, adjust, grease or replace if necessary

BEFORE EACH RIDE AND EVERY 2000 KM (1250 MI)

Action
Tyre pressure - Adjust
Brake pad wear - Check and clean, adjust or replace if necessary

AFTER RUN-IN (1,500 KM (932 MI)

Action
Exhaust pipe flange bolts - Check and clean, adjust, grease or replace if necessary
Transmission cables and controls - Check and clean, adjust, grease or replace if necessary
Steering bearings and steering clearance - Check and clean, adjust, grease or replace if necessary.
Disc brakes - Check and clean, adjust or replace if necessary
Engine oil filter - Replace
Fork - Check and clean, adjust and lubricate
General vehicle operation - Check and clean, adjust, grease or replace if necessary.
Braking systems - Check and clean, adjust, grease or replace if necessary
Light circuit - Check and clean, adjust or replace if necessary
Safety switches - Check and clean, adjust, grease or replace if necessary
Gearbox oil - Change
Engine oil - Change
Final transmission oil - Change
Tyres - Check and clean, adjust, grease or replace if necessary
Tyre pressure - Adjust
Engine revs at idle speed - Adjustment.
Valve clearance adjustment - Adjust
Wheels - Check and clean, adjust, grease or replace if necessary
Bolts, nuts and screws tightening - Check and clean, adjust, grease or replace if necessary
Battery terminals tightening - Check and clean, adjust, grease or replace if necessary
Cylinder synchronisation - Check and clean, adjust, grease or replace if necessary
Suspensions and setting - Check and clean, adjust, grease or replace if necessary
Brake pad wear - Check and clean, adjust or replace if necessary

EVERY 4 YEARS
Action
Fuel pipes - Replace
Brake pipes - Replacement

EVERY 5000 KM (3125 MI) - IF THE VEHICLE IS USED FOR RACING

Action
Outer spark plugs - Replace
Engine oil filter - Replace
Engine oil - Change
Purge fluid present in oil drainage pipe from the filter housing - Clean
Clutch wear - Check and clean, adjust, grease or replace if necessary

EVERY 10,000 KM (6250 MILES) OR 12 MONTHS

Action
Outer spark plugs - Replace
Idle mixture (CO) - Check and clean, adjust, grease or replace if necessary
Transmission cables and controls - Check and clean, adjust, grease or replace if necessary

MAIN - 29
Maintenance GRISO 1100

Action
Steering bearings and steering clearance - Check and clean, adjust, grease or replace if necessary.
Wheel bearings - Check and clean, adjust, grease or replace if necessary
Disc brakes - Check and clean, adjust or replace if necessary
Air filter - Check and clean, adjust, grease or replace if necessary
Engine oil filter - Replace
General vehicle operation - Check and clean, adjust, grease or replace if necessary.
Braking systems - Check and clean, adjust, grease or replace if necessary
Gearbox oil - Change
Engine oil - Change
Final transmission oil - Change
Valve clearance adjustment - Adjust
Wheels - Check and clean, adjust, grease or replace if necessary
Bolts, nuts and screws tightening - Check and clean, adjust, grease or replace if necessary
Cylinder synchronisation - Check and clean, adjust, grease or replace if necessary
Purge fluid present in oil drainage pipe from the filter housing - Clean
Fuel pipes - Check and clean, adjust, grease or replace if necessary
Brake pipes - Check and clean, adjust, grease or replace if necessary
Clutch wear - Check and clean, adjust, grease or replace if necessary

AFTER THE FIRST 10,000 KM (6,250 MILES) AND THEN AFTER EVERY 20,000 KM (12,500
MILES)
Action
Fork oil - Change
Fork oil seals - Replace

EVERY 20000 KM (12500 MILES) OR 24 MONTHS

Action
Inner spark plugs - Replace
Alternator belt - Adjust; EVERY 50,000 km (31,050 mi)
Air filter - Replace
Fork - Check and clean, adjust and lubricate
Brake fluid - change
Suspensions and setting - Check and clean, adjust, grease or replace if necessary
Brake pad wear - Check and clean, adjust or replace if necessary

Transmission fluid

Check

• Keep the vehicle upright with both wheels on the

ground.
• Unscrew and remove the cap/dipstick (1).
• The level is correct if the oil is close to the hole
of the cap/dipstick (1).
• If the oil is lower than specified, top-up until it
reaches the cap/dipstick hole (1).
CAUTION

DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCE TO

THE FLUID. WHEN USING A FUNNEL OR ANY OTHER EL-
EMENT, MAKE SURE IT IS PERFECTLY CLEAN.

MAIN - 30
GRISO 1100 Maintenance

Replacement
CAUTION
THE UNIT MUST BE HOT WHEN THE OIL IS CHANGED AS UNDER SUCH CONDITIONS OIL IS
FLUID AND THEREFORE EASY TO DRAIN.
NOTE
RIDE SOME km (miles) TO WARM UP ENGINE OIL
• Place a container with + 400 cm³ (25 cu in) capacity under the drainage plug (3).
• Unscrew and remove the drainage plug (3).
• Unscrew and remove the breather cap (2).
• Drain the oil into the container; allow several minutes for oil to drain out completely.
• Check and if necessary, replace the sealing washer of drainage plug (3).
• Remove any metal scrap attached to the drainage plug (3) magnet.
• Screw and tighten the drainage plug (3).
• Pour new oil through the fill opening (1) until it reaches the cap/dipstick hole (1).
CAUTION
DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCE TO THE FLUID. WHEN USING A FUNNEL
OR ANY OTHER ELEMENT, MAKE SURE IT IS PERFECTLY CLEAN.
• Screw and tighten the caps (1 - 2).

Engine oil

Check
CAUTION
ENGINE MUST BE WARM TO CHECK ENGINE OIL LEVEL.
NOTE
DO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT STANDSTILL TO WARM UP THE ENGINE
OIL AND REACH THE OPERATING TEMPERATURE OF ENGINE OIL. OIL IS BEST CHECKED
AFTER RUNNING FOR ABOUT 15 KM (10 miles).
• Shut off the engine.
• Keep the vehicle upright with the two wheels on the ground.
• Unscrew and remove the dipstick (1).
• Clean the dipstick (1).
• Reinsert the dipstick (1) into the opening but do not screw it.

MAIN - 31
Maintenance GRISO 1100

• Remove the dipstick (1).

• Check oil level on the dipstick (1).
• The oil level is correct when it close to the "MAX" mark.

MAX = maximum level

MIN = minimum level
Add engine oil if required:

• Unscrew and remove the dipstick (1).

• Top-up with engine oil until it goes above the minimum level marked "MIN".
CAUTION
DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCE TO
THE FLUID. WHEN USING A FUNNEL OR ANY OTHER EL-
EMENT, MAKE SURE IT IS PERFECTLY CLEAN.

Replacement
NOTE
HOT OIL IS MORE FLUID AND WILL DRAIN OUT MORE EASILY AND COMPLETELY.
• Place a container with + 4000 cm³ (245
cu in) capacity under the drainage plug
(2).
• Unscrew and remove the drainage
plug (2).

• Unscrew and remove the filler plug (3).

• Drain the oil into the container; allow
several minutes for oil to drain out com-
pletely.
• Check and if necessary, replace the
sealing washers of drainage plug (2).
• Remove any metal scrap attached to
the drainage plug (2) magnet.

MAIN - 32
GRISO 1100 Maintenance

• Screw and tighten the drainage plug

(2).
• Pour new oil until it goes above the
minimum level marked "MIN".

Engine oil filter

• Unscrew and remove the engine oil fil-

ter from its seat.
NOTE
NEVER REUSE AN OLD FILTER.

• Spread a thin layer of oil on the sealing ring of the new engine oil filter.
• Fit and screw the new oil filter in its seat.

Gearbox Oil

Inspection

CHECKING AND TOPPING UP

CAUTION
ENGINE MUST BE WARM TO CHECK GEARBOX OIL LEVEL.
NOTE
DO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT STANDSTILL TO WARM UP THE ENGINE
OIL AND REACH THE OPERATING TEMPERATURE OF ENGINE OIL. OIL IS BEST CHECKED
AFTER RUNNING FOR ABOUT 15 KM (10 miles).
• Shut off the engine.
• Keep the vehicle upright with both
wheels on the ground.
• Undo and remove the dipstick opening
(1) located on the right side of the gear-
box.
• The level is correct if the oil is close to
the hole of the dipstick (1).

If necessary:

MAIN - 33
Maintenance GRISO 1100

• Top-up with oil until it reaches the dip-

stick opening (1).
CAUTION
DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCE TO
THE FLUID. WHEN USING A FUNNEL OR ANY OTHER EL-
EMENT, MAKE SURE IT IS PERFECTLY CLEAN.

Replacement
NOTE
HOT OIL IS MORE FLUID AND WILL DRAIN OUT MORE EASILY AND COMPLETELY.
• Place a container with suitable capacity under the
drainage plug (2).
• Unscrew and remove the drainage plug (2).
• Unscrew and remove the filler cap (1).
• Drain the oil into the container; allow several mi-
nutes for oil to drain out completely.
• Check and replace, if necessary, the sealing
washers of drainage plug (2).
• Remove any metal scrap attached to the drain-
age plug (2) magnet.
• Screw and tighten the drainage plug (2).
• Pour in new oil until it reaches the dipstick open-
ing (1).
• Tighten the filler cap (1).
CAUTION
DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCE TO
THE FLUID. WHEN USING A FUNNEL OR ANY OTHER EL-
EMENT, MAKE SURE IT IS PERFECTLY CLEAN.

Air filter

• Disconnect the air temperature sensor

connector.

MAIN - 34
GRISO 1100 Maintenance

• Slide off and remove the main fuse box

from its holder.

• Undo and remove the six screws.

• Lift the filter housing cover.

• Remove the air filter frame.

MAIN - 35
Maintenance GRISO 1100

• Remove the air filter.

• Plug the intake duct with a clean cloth
to prevent any foreign objects from en-
tering the intake manifold.

DO NOT START THE ENGINE WITHOUT THE AIR FILTER.

TO CLEAN THE FILTERING ELEMENT, USE A PRESSURE
AIR JET FROM THE INSIDE TO THE OUTSIDE.

Checking the valve clearance

If the timing system is very noisy, check the clearance between the valves and the rocking levers.
NOTE
ADJUST WITH COLD ENGINE, WITH PISTON AT TOP DEAD CENTRE (TDC) IN COMPRESSION
STROKE (VALVES CLOSED).
• Unscrew and remove the three screws
and remove the fairing.

• Working on both sides, unscrew and

remove the two external screws and
remove the spark plug cap.

MAIN - 36
GRISO 1100 Maintenance

• Working from both sides, unscrew and

remove the two internal screws and re-
move the insert.

• Disconnect both spark plug caps.

• Unscrew and remove the eight screws.

• Remove the head cover.

MAIN - 37
Maintenance GRISO 1100

• Loosen the nut (1).

• Use a screwdriver on the set screw (2)
until the following clearances are ob-
tained:

Inlet valve: 0.10 mm (0.0039 in)

Outlet valve: 0.15 mm (0.0059 in)

• The measurement must be done using

a thickness gauge (3).
CAUTION
IF CLEARANCE IS LARGER THAN RECOMMENDED, THE
TAPPETS WILL BE NOISY. OTHERWISE, THE VALVES DO
NOT CLOSE CORRECTLY, WHICH CAN LEAD TO PROB-
LEMS SUCH AS:
• PRESSURE DROP;
• ENGINE OVERHEAT;
• VALVE BURN OUT, ETC.

Braking system

Level check

Brake fluid check

• Rest the vehicle on its stand.

• For the front brake, 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 same
level with the plug.
• Make sure that the fluid level in the reservoir is above the "MIN" reference mark:

MIN = minimum level

MAX = maximum level
If the fluid does not reach at least the "MIN" reference mark:

• Check brake pads and disc for wear.

• If the pads and/or the disc do not need replacing, top-up the fluid.

MAIN - 38
GRISO 1100 Maintenance

Top-up

Front brake:

• Unscrew the two screws (1) of the

brake fluid reservoir (2) using a Phillips
screwdriver.
• Lift and remove the cover (3) and
screws (1) as well.
• Remove the gasket (4).

Rear brake:

• Unscrew and remove the cap (5).

• Remove the gasket (6).
• Top-up the reservoir with brake fluid to
the correct level, which is between the
two "MIN" and "MAX" reference marks.

RISK OF BRAKE FLUID SPILLS. DO NOT OPERATE THE

BRAKE LEVER WITH BRAKE FLUID RESERVOIR CAP
LOOSENED OR REMOVED.
CAUTION

AVOID PROLONGED AIR EXPOSURE OF THE BRAKE

FLUID. BRAKE FLUID IS HYGROSCOPIC AND ABSORBS
MOISTURE WHEN IN CONTACT WITH AIR. LEAVE THE
BRAKE FLUID RESERVOIR OPEN ONLY FOR THE TIME
NEEDED TO COMPLETE THE TOPPING UP PROCEDURE.

TO AVOID SPILLING FLUID WHILE TOPPING-UP, KEEP

THE TANK PARALLEL TO THE RESERVOIR EDGE (IN
HORIZONTAL POSITION).

DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCE TO

THE FLUID.

WHEN USING A FUNNEL OR ANY OTHER ELEMENT,

MAKE SURE IT IS PERFECTLY CLEAN.

DO NOT EXCEED THE "MAX" LEVEL MARK WHEN TOP-

PING UP.
TOP-UP TO "MAX" LEVEL MARK ONLY WHEN BRAKE
PADS ARE NEW. WHEN TOPPING UP DO NOT EXCEED
THE "MAX" LEVEL MARK WHEN BRAKE PADS ARE
WORN AS YOU RISK SPILLING FLUID WHEN CHANGING
THE BRAKE PADS.
CHECK BRAKING EFFICIENCY. IN CASE OF EXCESSIVE
TRAVEL OF THE BRAKE LEVER OR POOR PERFORM-
ANCE OF THE BRAKING SYSTEM, TAKE YOUR VEHICLE
TO AN Official Moto Guzzi Dealer, AS IT MAY BE NECES-
SARY TO PURGE THE AIR IN THE SYSTEM.

MAIN - 39
Maintenance GRISO 1100

MAIN - 40
INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

Electrical system GRISO 1100

Components arrangement

Key:
1 Coil
2 Instrument panel
3 Fuel pump
4 Injector

ELE SYS - 42
GRISO 1100 Electrical system

5 Throttle valve potentiometer

6 Fall sensor
7 Rear light
8 Main fuses
9 Lambda probe
10 Battery
11 Starter motor
12 Intake air temperature sensor
13 Engine revolution sensor
14 Head temperature sensor
15 Engine control unit
16 Instrument panel air temperature sensor
17 Front headlamp
18 Alternator
19 Oil pressure sensor
20 Speed sensor
21 Auxiliary fuses

Electrical system installation

ELE SYS - 43
Electrical system GRISO 1100

General wiring diagram

Key:
1 Multiple connectors
2 Diode pre-installation
3 Start-up relay
4 Clutch switch
5 Lights relay

ELE SYS - 44
GRISO 1100 Electrical system

6 Right light switch

7 Condenser pre-installation
8 Horn
9 Left light switch
10 Instrument panel air temperature thermistor
11 Instrument panel
12 Instrument panel diagnosis
13 Key switch
14 Immobilizer aerial
15 Right rear turn indicator
16 Rear light (with LED)
17 Left rear turn indicator
18 License plate light
19 Rear stop switch
20 Front stop switch
21 (ECU) Diagnosis connector
22 Secondary fuses
23 Main fuses
24 Starter motor
25 Battery
26 -
27 Alternator
28 Main injection relay
29 Secondary injection relay
30 Oil pressure bulb
31 Gear in neutral switch
32 Lambda probe
33 Side stand switch
34 Fuel reserve sensor
35 Fuel pump
36 Intake air temperature thermistor
37 Head temperature thermistor
38 Automatic air
39 Throttle sensor
40 Right cylinder inner spark plug
41 Right cylinder outer spark plug
42 Left cylinder inner spark plug
43 Left cylinder outer spark plug

ELE SYS - 45
Electrical system GRISO 1100

44 Right cylinder double coil

45 Left cylinder double coil
46 Right cylinder injector
47 Left cylinder injector
48 Speed sensor
49 Fall sensor
50 Flywheel pick up
51 Pick up cable shielding
52 ECU control unit
53 Left front turn indicator
54 Tail light bulb
55 Low-/high-beam light bulb
56 Front headlamp
57 Right front turn indicator
58 GPS attachment (if fitted)

Cable colour:
Ar orange
Az sky blue
B blue
Bi white
G yellow
Gr grey
M brown
N black
R red
Ro pink
V green
Vi purple

Checks and inspections

Dashboard

Diagnosis

Changing the CODE

If you know the code, just enter it and then a new code that will be automatically stored in the memory.
If the vehicle is new, the user code is: 00000

ELE SYS - 46
GRISO 1100 Electrical system

Resetting the CODE

This function is used to set a new code when the old one is not available; in this case, at least two of
the programmed keys have to be inserted in the ignition lock.
After the first key has been inserted, the second one is requested with the following message:
INSERT KEY II
If the second key is not inserted within 20 seconds, the operation is finished.
After recognising the second key, the new code is required with the message:
ENTER NEW CODE
Once the operation is finished, the instrument panel goes back to the SET-UP menu.
DIAGNOSIS
Access to this menu (diagnosis functions), for the technical service only, after requesting a service code.
It will read: ENTER SERVICE CODE. The code for Griso 1100 is: 12425
The functions in this menu are
• Exit
• ECU Diagnosis
• Instrument panel errors
• Delete errors
• Reset Service
• Update
• Key change
• km / miles
ECU ERRORS
The instrument panel receives only the current errors from the control unit.
Description Error code
Throttle Valve Error DC V DC ECU 10
Throttle Valve Error DC Gnd ECU 11
Engine Temperature Error DC V DC ECU 14
Engine Temperature Error DC Gnd ECU 15
Air Temperature Error DC V DC ECU 16
Air Temperature Error DC Gnd ECU 17
Low Battery Error ECU 20
Lambda Probe Error ECU 21
Coil 1 Error DC V DC ECU 22
Coil 1 Error DC Gnd ECU 23
Coil 2 Error DC V DC ECU 24
Coil 2 Error DC Gnd ECU 25
Injector 1 Error DC V DC ECU 26
Injector 1 Error DC Gnd ECU 27

ELE SYS - 47
Electrical system GRISO 1100

Injector 2 Error DC V DC ECU 30

Pump Relay Error ECU 36
Local Loopback Error ECU 37
Start-up Remote Error DC V DC ECU 44
Remote Error Start-up DC Gnd ECU 45
Canister Error DC V DC ECU 46
Canister Error DC Gnd ECU 47
Battery Error Hig ECU 50
Generic ECU Error ECU 51
Signal Panel Error ECU 54
Self-adaptability Value Error ECU 55
Vehicle Speed Error ECU 56
Stepper Error AC ECU 60
Stepper Error DC V DC ECU 61
Stepper Error DC Gnd ECU 62
Not recognised error ECU 00

INSTRUMENT PANEL ERRORS

In this mode a chart is displayed showing potential errors in the immobilizer and its sensors.
This is the error decoding chart:

Description: Immobilizer failure: Key code read but not recognised. Error code: DSB 01
Description: Immobilizer failure: Key code not read (Key not inserted or transponder broken) Error code:
DSB 02
Description: Immobilizer failure: Aerial not working (Open or short-circuited). Error code: DSB 03
Description: Immobilizer failure: Internal controller failure. Error code: DSB 04
Description: - Error code: DSB 05
Description: Air temperature sensor failure. Error code: DSB 06
Description: Oil sensor failure. Error code: DSB 07
Description: Oil pressure failure. Error code: DSB 08
The instrument panel keeps all previous errors stored in its memory.

DELETE ERRORS
This option deletes instrument panel errors only, a further confirmation is requested.

ELE SYS - 48
GRISO 1100 Electrical system

INSTRUMENT PANEL SOFTWARE UPGRADE

This function is used to program the instrument
panel again with a new software through Axone.
The Display reads: "Instrument panel disconnec-
ted. Now connect the diagnosis instrument"; the
instrument panel will connect normally after the
key is extracted-inserted.
The white connector is placed under the saddle,
beside the fuse box, close to the diagnosis con-
nector for the injection system.
Use the Ditech connector in the Axone 2000 Apri-
lia-Moto Guzzi package to connect to the Axone
cable.

KEY CHANGE FUNCTION

This function can be used:
1) if one key is lost; the dealer can disable this key;
2) to activate up to 4 keys;
3) should a new key lock be necessary and thus program the new set of keys.
In the first phase the user code must be entered and, after confirming the inserted key (key I) has been
programmed, the other keys must be entered too.
The procedure finishes once the 4 keys have been programmed or after 20 seconds.
Should a new key lock be necessary, the procedure is: once the key is set to ON but the instrument
panel does not recognise it, the user code is requested: enter the user code.
Now enter MENU, DIAGNOSIS (entering the service code), KEY CHANGE and program the new keys.

Battery recharge circuit

Checking the stator

Single-phase generator with regulated voltage

Maximum load 40A (550W)
Charging voltage 14.2 - 14.8 V (5000 rpm)

ELE SYS - 49
Electrical system GRISO 1100

Start-up system check

pick-up input about 100 A

level indicators

Petrol pump:
Input: 3.5 A (to be measured between pins 1 and
2 with 12V voltage)
Fuel level sensor:
Resistance (to be measured between pins 3 and
4)
250-300 Ohm with fuel level equal to 0 litre
100 Ohm with fuel level equal to 11.25 litres (20.43
pt)
10-20 Ohm with fuel level equal to 22.5 litres
(40.86 pt)
The low fuel warning light turns on with values over
230 Ohm.

In case there is anomaly on the fuel probe, the low fuel warning light flashes on the instrument panel.
The alarm warning light on the instrument panel does not light up and the word Service is not displayed.

Lights list

FRONT HEADLAMP
Tail light: 12V - 5W
Low-beam light: 12V - 55W
High-beam light: 12 V - 60 W H4

ELE SYS - 50
GRISO 1100 Electrical system

REAR LIGHT
LED

Fuses

AUXILIARY FUSES
A - Stop, horn, coil, light relay (15 A).
B - Tail lights, license plate light, passing (15 A).
C - Fuel pump, coils, injectors, start-up relay (20
A).
D - Lambda burner, secondary injection relay coil,
start-up relay coil, speed sensor power supply,
ECU control unit power supply, engine kill (15 A).
E - Permanent positive, ECU power supply (3A).
F - "Tom - Tom" (3A) (if fitted)
NOTE
THERE ARE THREE SPARE FUSES (3, 15, 20 A).

MAIN FUSES
1 - From battery to voltage regulator (30 A).
2 - From battery to key and auxiliary fuses C - D
(30 A).
NOTE
THERE IS ONE SPARE FUSE.

ELE SYS - 51
Electrical system GRISO 1100

Control unit

Model: Magneti Marelli IAW 5 AM2

Black connector pins

Pin Use
1 Not used
2 Not used
3 Ignition potentiometer signal
4 Not used
5 Engine temperature signal
6 Not used
7 Not used
8 Not used
9 Stepper motor (+)
10 Right cylinder coil control
11 Not used
12 Not used
13 Not used
14 Air temperature signal
15 Not used
16 Not used
17 Stepper motor (+)
18 Stepper motor (-)
19 Stepper motor (-)
20 5V power supply (NTC sensors)
21 Not used
22 Not used
23 Neutral sensor signal
24 Not used
25 Engine revolution sensor signal
26 Not used
27 Not used
28 Left cylinder injector control
29 Ignition potentiometer power supply
30 Not used
31 Not used
32 Ignition potentiometer negative
33 Not used

ELE SYS - 52
GRISO 1100 Electrical system

34 Revolution sensor anti-jamming cable

35 Engine revolution sensor signal
36 Not used
37 Right cylinder injector control
38 Left cylinder coil control
Grey connector pins
Pin Use
1 Pin 85 ignition relay control
2 Not used
3 Not used
4 Power supply protected from instrument panel
5 Not used
6 Pin 86 auxiliary relay control
7 Immobilizer line
8 Pin 85 ignition relay control
9 Not used
10 Not used
11 Oxygen probe negative control
12 Not used
13 Not used
14 Not used
15 Not used
16 K line (diagnosis)
17 Power supply from main relay
18 Not used
19 Not used
20 CAN - H line (ccm/instrument panel)
21 Not used
22 Oxygen probe signal
23 Not used
24 Vehicle speed signal input
25 Not used
26 Not used
27 "Engine stop" signal input
28 Ignition signal input
29 CAN - L line (ccm/instrument panel)
30 Not used
31 Not used

ELE SYS - 53
Electrical system GRISO 1100

32 Oxygen probe power supply

33 Clutch sensor signal
34 Not used
35 Fall sensor signal
36 Not used
37 Not used
38 Side stand sensor signal

Battery

12 V - 18 Ampere/hour

Speed sensor

Active inductive sensor

3-pin connector (Power supply - Signal-Earth con-
nection).

ELE SYS - 54
GRISO 1100 Electrical system

Engine rpm sensor

Measures the engine revolution speed and each

cylinder timing in relation to the TDC
Inductive type sensor, with three-way connector:

• positive voltage pin;

• negative voltage pin: resistance from
650 to 720 Ohm (to be measured be-
tween pins 1 and 2);
• shielding pin.

Air gap value: (measure sensor length with a depth

gauge): 0.5 - 0.7 mm (0.0197 - 0.0276 in).

Throttle position sensor

Output voltage 0.55 - 4.4 V (variable depending on

the position of the throttle valve, to be measured
between pins C and A)

Engine temperature sensor

This sensor, 5V powered, features NTC specifications and sends the control unit a signal which varies
depending on temperature to help manage the stoichiometric ratios during engine speed adjustment.

ENGINE TEMPERATURE SENSOR RESISTANCE

Specification Desc./Quantity
1 Resistance at -40 °C (-40 °F) 100.950 kOhm
2 Resistance at -30 °C (-22 °F) 53.100 kOhm
3 Resistance at -20 °C (-4 °F) 29.120 kOhm
4 Resistance at -10 °C (14 °F) 16.600 kOhm
5 Resistance at 0 °C (32 °F) 9.750 kOhm
6 Resistance at +10 °C (50 °F) 5.970 kOhm
7 Resistance at +20 °C (68 °F) 3.750 kOhm
8 Resistance at +30 °C (86 °F) 2.420 kOhm
9 Resistance at +40 °C (104 °F) 1.600 kOhm
10 Resistance at +50 °C (122 °F) 1.080 kOhm
11 Resistance at +60 °C (140 °F) 0.750 kOhm
12 Resistance at +70 °C (158 °F) 0.530 kOhm
13 Resistance at +80 °C (176 °F) 0.380 kOhm
14 Resistance at +90 °C (194 °F) 0.280 kOhm
15 Resistance at +100 °C (212 °F) 0.204 kOhm
16 Resistance at +110 °C (230 °F) 0.153 kOhm

ELE SYS - 55
Electrical system GRISO 1100

Specification Desc./Quantity
17 Resistance at +120 °C (257 °F) 0.102 kOhm

Air temperature sensor

NTC type sensor

AIR TEMPERATURE SENSOR RESISTANCE

Specification Desc./Quantity
1 Resistance at -40 °C (-40 °F) 100.950 kOhm
2 Resistance at 0 °C (32 °F) 9.750 kOhm
3 Resistance at 10 °C (50 °F) 5.970 kOhm
4 Resistance at 20 °C (68 °F) 3.750 kOhm
5 Resistance at 30 °C (86 °F) 2.420 kOhm
6 Resistance at 40 °C (104 °F) 1.600 kOhm
7 Resistance at 90 °C (194 °F) 0.280 kOhm

Lambda sensor

Oxygen sensor with heater.

Sensor voltage between 0 and 0.9 V (to be meas-
ured between pins 1 and 2).
Heater resistance 12.8 Ohm (to be measured be-
tween pins 3 and 4 at 20°C - 68°F).

ELE SYS - 56
GRISO 1100 Electrical system

Injector

Resistance 14 Ohm ± 2 Ohm measured at 20 °C

(68 °F)

Coil

Characteristic
Primary resistance:
0.9 - 1.1 Ω (measured between pins 1 and 15)
Secondary resistance:
6.5 - 7.2 KΩ.

Engine oil pressure sensor

An oil pressure sensor anomaly is signalled by the

lighting of the "bulb" icon which should remain lit
even with the engine running.
There is an oil pressure anomaly when, with en-
gine running at over 1500 rpm, the sensor is de-
tected as conducting (closed) at least for one
second.
At lower rpm, there is an anomaly when the sensor
remains closed for at least 300 seconds. The
opening of the sensor, and therefore the alarm
triggering, is detected if the contact is open for at
least one second.

ELE SYS - 57
Electrical system GRISO 1100

Bank angle sensor

Normally open contact, 62 kOhm resistance, with
vehicle upright (straight sensor); Closed contact, 0
Ohm resistance, when the sensor is turned by 90°
with respect to its fitting position.

Air temperature sensor - instrument panel

Characteristic
Resistance
10 kOhm (at 25°C - 77°F)
Resistance
32.5 kOhm (at 0°C - 32°F)

Connectors

Dashboard
The pin configuration of the grey-bodied connector is as follows:
PIN USE
1 + KEY
2 RIGHT TURN INDICATOR CONTROL
3 HIGH-BEAM LIGHT INPUT
4-
5-
6 K LINE
7-
8 SELECT 1 - SET
9 FUEL LEVEL SENSOR
10 AIR TEMPERATURE SENSOR
11 + BATTERY
12 LEFT TURN INDICATOR CONTROL

ELE SYS - 58
GRISO 1100 Electrical system

13 -
14 -
15 -
16 GENERAL EARTH CONNECTION
17 OIL PRESSURE SENSOR INTAKE
18 SENSORS EARTH CONNECTION
19 GENERAL GROUND (OPTIONAL)
20 GENERAL GROUND (OPTIONAL)
The pin configuration of the black-bodied connector is as follows:
PIN USE
21 + BATTERY
22 LEFT FRONT TURN INDICATOR ACTIVATION
23 LEFT REAR TURN INDICATOR ACTIVATION
24 AERIAL 1
25 -
26 CAN H
27 -
28 LIGHTS RELAY ACTIVATION
29 -
30 SELECT 2
31 + BATTERY
32 RIGHT FRONT TURN INDICATOR ACTIVATION
33 RIGHT REAR TURN INDICATOR ACTIVATION
34 AERIAL 2
35 -
36 CAN L
37 -
38 -
39 -
40 SELECT 3

ELE SYS - 59
Electrical system GRISO 1100

ELE SYS - 60
INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

Engine from vehicle GRISO 1100

Vehicle preparation

Before removing the engine block, proceed as fol-

lows:

• Hold the vehicle steady with a stand

from the front and belts fixed to a hoist
from the rear.
• Place the engine service stand under
the oil sump.
• Remove the whole exhaust, the air fil-
ter housing, the fork together with the
cardan shaft, the fuel tank side fairings,
the spark plug covers and disconnect
the spark plug tubes.
• Empty the clutch control fluid through
the bleed pipe located under the sad-
dle.

Removing the engine from the vehicle

• Working on both sides disconnect the

injector connectors.

• Disconnect the throttle cables

ENG VE - 62
GRISO 1100 Engine from vehicle

• Disconnect the idle motor connector.

• Disconnect the engine temperature

sensor connector

• Disconnect the throttle valve position

sensor connector

• Unscrew and remove the two screws

and collect the washer.
• Disconnect the revolution sensor con-
nector and collect the gasket.

ENG VE - 63
Engine from vehicle GRISO 1100

• Disconnect the alternator connectors.

• Disconnect the gear in neutral sensor

connector.

• Undo and remove the two screws and

collect the washers.
• Remove the starter motor cover.
• Unscrew and remove the stud bolt.
• Disconnect the ground leads.

• Disconnect the connectors of the start-

er motor.

ENG VE - 64
GRISO 1100 Engine from vehicle

• Unscrew and remove the three screws

and remove the clutch control cylinder.

• Slide off the gearbox oil breather pipe.

• Working on both sides, release the

clamp and slide off the engine oil
breather pipe.

• Remove the oil vapour connecting

pipe.
• Unscrew and remove the two screws
fixing the oil vapour connecting pipe.

ENG VE - 65
Engine from vehicle GRISO 1100

• Disconnect the stand sensor connec-

tor and release it from the clamps.

• Undo and remove the two screws and

remove the control unit protection.
• Undo and remove the two screws and
move the control unit downwards.

• Undo and remove the screws and

move the oil vapour recovery reservoir.
• Unscrew and remove the stud bolt.

• Unscrew and remove the engine lower

fixing nut and collect the washer.
• Remove the lower bolt and collect the
washer.

ENG VE - 66
GRISO 1100 Engine from vehicle

• Working on both sides, unscrew and

remove the front screw and collect the
washer.

• Unscrew and remove the upper nut fix-

ing the engine and collect the washer.
• Remove the upper pin and collect the
washer.

• Unscrew and remove the nut and col-

lect the screw and the cable guide.
• Unscrew and remove the screw and
then remove the plate.
CAUTION
PERFORM THE OPERATIONS BELOW AIDED BY A SEC-
OND OPERATOR.

• Lower the engine partially.

• Disconnect the oil pressure sensor
connector.
• Fully lower the engine.
• Lift the rear part of the vehicle.
• Remove the front stand.
• Unhook the belts from the hoist holding
the rear part of the vehicle and remove
the chassis from the engine.

ENG VE - 67
Engine from vehicle GRISO 1100

Installing the engine to the vehicle

• Secure the vehicle chassis with a hoist

and onto a front stand and lift the en-
gine to place it in position.
• Connect the oil pressure sensor con-
nector.

• Fit the plate and tighten the screw.

• Insert the screw, the cable guide and
screw the nut.

• Working from the right side, insert the

washer and the upper bolt.
• Fit the washer and insert the engine
upper fixing nut.

• Working on both sides, insert the

washer and screw the screw without
tighten it.

ENG VE - 68
GRISO 1100 Engine from vehicle

• Working from the right side, fit the

washer and insert the lower bolt.
• Fit the washer and tighten the engine
lower fixing nut.

• Working on both sides, tighten the front screw to the prescribed torque.

• Tighten the stud bolt.

• Place the oil vapour recovery reservoir

and tighten the screw.

• Fit the control unit and tighten the two

screws.
• Fit the control unit cover and tighten the
two screws.

• Connect the stand sensor connector

and fix it to the chassis with new
clamps.

ENG VE - 69
Engine from vehicle GRISO 1100

• Fit the oil vapour attachment pipe and

tighten the two fixing screws.

• Insert the oil breather pipe and fasten

it with a new clamp.

• Fit the gearbox oil breather pipe.

• Fit the clutch control cylinder.

• Tighten the three screws.

ENG VE - 70
GRISO 1100 Engine from vehicle

• Fit the clutch bleed pipe on the cable

guide.
• Fill up the clutch system.

• Connect the starter motor connectors.

• Connect the ground cables and tighten

the screw.
• Fit the starter motor cover.
• Place the two washers and tighten the
two screws.

• Connect the neutral sensor connector.

ENG VE - 71
Engine from vehicle GRISO 1100

• Connect the alternator connectors.

• Fit the gasket and connect the revolu-

tion sensor connector.
• Fit the washer and tighten the two
screws.

• Connect the throttle valve position sen-

sor connector.

• Connect the engine temperature sen-

sor connector.

ENG VE - 72
GRISO 1100 Engine from vehicle

• Connect the idle motor connector.

• Connect and adjust the throttle grip ca-
ble clearance.

• Working on both sides, connect the in-

jector connectors.
• Working on both sides, connect the
spark plug tubes.
• Working from both sides, fit the insert
and tighten the two internal screws.
• Working from both sides, fit the spark
plug cover and tighten the two external
screws.
• Install the fuel tank.
• Fit the saddle.
• Working from both sides, fit the fairing
and tighten the three screws.
• Fit the fork together with the cardan
shaft.
• Install the whole exhaust, the air filter
housing, the fuel tank and the saddle.

ENG VE - 73
INDEX OF TOPICS

ENGINE ENG
GRISO 1100 Engine

Gearbox

Diagram

KEY:
1. Ball bearing
2. Circlip

ENG - 75
Engine GRISO 1100

3. Shim washer
4. Pin
5. Desmodromic compl.
6. Ball bearing
7. Spring
8. Spacer
9. Circlip
10. Fifth wheel
11. Linking pin
12. Gear
13. Circlip
14. Shoulder washer
15. Ball bearing cage
16. Gear
17. Sealing ring
18. Ball bearing
19. Gear
20. Circlip
21. Washer
22. Half ring
23. Oil cap
24. Washer
25. Gearbox
26. Aluminium gasket
27. Bleed cap
28. Neutral sensor
29. Gasket
30. Sealing ring
31. Bushing
32. Gasket
33. Oil drainage cap
34. Roller bearing
35. Circlip
36. Belleville spring
37. Pressure plate
38. Shaped washers
39. Sleeve
40. Circlip

ENG - 76
GRISO 1100 Engine

41. Transmission gear

42. Ball bearing
43. Gear
44. Gear
45. Ball bearing cage
46. Shoulder washer
47. Circlip
48. Gear
49. Circlip
50. Gear
51. Main shaft
52. Transmission gear
53. Ring nut
54. Washer
55. Clutch internal body
56. Sealing ring
57. Ball bearing
58. O-Ring
59. Clutch shaft
60. Fork
61. Fork shaft
62. Fork
63. Fork
64. Gear
65. Gear
66. Ball bearing
67. Secondary shaft
68. Gear
69. Spacer
70. Spring
71. Index lever
72. Bushing
73. Pre-selector compl.
74. Spring

Gearbox

ENG - 77
Engine GRISO 1100

Removing the gearbox

• Remove the starter motor.

• Make sure the transmission is in idle.
• Undo and remove the screw and re-
move the gearbox lever.

• Unscrew and remove the cap.

• Place a container of suitable capacity

under it, unscrew and remove the cap
and then bleed all gearbox oil.

• Unscrew and remove the three screws.

ENG - 78
GRISO 1100 Engine

• Unscrew and remove the two screws.

• Unscrew and remove the screw.

• Remove the gearbox.

See also
Removing the
starter motor
Replacement

Gearbox shafts

ENG - 79
Engine GRISO 1100

Disassembling the gearbox

• Remove the gearbox.

• Place the gearbox on the specific gearbox support tool and on a vice.

Specific tooling
05.90.25.30 Gearbox support

• Unscrew and slide off the odometer

gear and collect the abutment washer
that is inside the gearbox.

• From the outside, slide off the thrust

cylinder and collect the O-Ring and the
washer.

• Remove the thrust bearing and the

washer.

ENG - 80
GRISO 1100 Engine

• Slide off the two bushings (1) and re-

move the rod (2), collect the bushing
(3).

• Fold the washer fins.

• Using the adequate ring nut spanner and the clutch body locking tool, unscrew and remove
the ring nut, and collect the clutch internal body.

Specific tooling
GU14912603 Hook spanner for fixing ring nut of the clutch shaft internal body
30.91.28.10 Clutch body locking

• Open the gearbox using the specific

tool.

Specific tooling
05.91.25.30 Gearbox opening

ENG - 81
Engine GRISO 1100

• Release the spring.

• Pressing the selector, slide off the

whole transmission lever.

• Unscrew and remove the threaded ref-

erence pin.

• Use rubber bands to tie down the trans-

mission shaft unit and extract it.

ENG - 82
GRISO 1100 Engine

• Remove the bearings from the gearbox

if necessary.

• Once the transmission shaft unit is in

on a bench, remove the rubber bands,
being careful with the group.
• Detach the shafts and label the forks
before removal.

• Remove the forks and collect the shaft.

ENG - 83
Engine GRISO 1100

• Replace bearings if necessary and re-

move the clutch shaft.

Removing the primary shaft

• Remove the main shaft.

• Operate on the main shaft from the
second gear side.

ENG - 84
GRISO 1100 Engine

• Remove the gear of the second gear

and collect the ball bearing cage.

• Remove the gear of the sixth gear and

collect the shoulder washer.

• Remove the circlip.

• Remove the gear of the third and fourth

gears.

ENG - 85
Engine GRISO 1100

• Remove the circlip and collect the

shoulder washer.

• Remove the gear of the fifth gear and

collect the ball bearing cage.

• Heat the shaft with a specific heater

and remove the helical transmission
gear.

Removing the secondary shaft

• Remove the transmission shaft.

• Operate on the shaft from the grooved
side.

ENG - 86
GRISO 1100 Engine

• Remove the shoulder washer.

• Remove the gear of the second gear

and collect the ball bearing cage and
the shoulder washer.

• Remove the circlip.

• Remove the gear of the sixth gear.

ENG - 87
Engine GRISO 1100

• Remove the circlip and collect the

shoulder washer.

• Remove the gear of the fourth gear and

collect the ball bearing cage.

• Remove the gear of the third gear and

collect the ball bearing cage and the
shoulder washer.

• Remove the circlip.

ENG - 88
GRISO 1100 Engine

• Remove the gear of the fifth gear.

• Remove the circlip, the shoulder wash-

er and remove the gear of the first gear,
collect the ball bearing cage.
• Remove the bearing if necessary.

See also
Disassembling the gearbox

Disassembling the clutch shaft

• Remove the gearbox from the engine

block.
• Remove the gearbox.
• Insert the clutch shaft in the special tool
for removal.

Specific tooling
000019663300 Tool for clutch shaft removal

• Compress the Belleville springs (10) until releasing the two half-rings (12).
• Remove the Belleville springs (10).
• Remove the washer (11).
• Remove the shaped washers (8).
• Remove the sleeve (7).
• Remove the circlip (6).
• Remove the transmission gear (5).
• Collect the clutch shaft (4).
CAUTION

ENG - 89
Engine GRISO 1100

VEHICLES WITH CHASSIS NUMBER FROM ZGULS00096M112690 TO ZGULS00096M113440

MAY PRESENT SOME NOISE PROBLEMS AT IDLE SPEED.
TO REDUCE THIS NOISE, ON THE CLUTCH SHAFT, FIT TWO SHAPED WASHERS (8) BESIDES
THE ONE ALREADY PRESENT IN THE ASSEMBLY

Checking the primary shaft

Measure coaxiality of the main shaft with a dial

gauge and a centring device and replace it if not
complying with specifications.

Characteristic
Shaft coaxiality limit
0.08 mm (0.0031 in)

Check transmission gears for signs of pitting and wear and replace damaged gears if necessary.
Check the gear fitting teeth for cracks, damage and wear and replace those damaged if necessary.
Check the transmission gears movement and, if it is not regular, replace the damaged part.

ENG - 90
GRISO 1100 Engine

Checking the secondary shaft

Measure the coaxiality of the transmission shaft

with a dial gauge and a centring device and re-
place it if not complying with specifications.

Characteristic
Shaft coaxiality limit
0.08 mm (0.0031 in)

Check transmission gears for signs of pitting and wear and replace damaged gears if necessary.
Check the gear fitting teeth for cracks, damage and wear and replace those damaged if necessary.
Check the transmission gears movement and, if it is not regular, replace the damaged part.

Checking the desmodromic drum

Check gear drum for damage, scratches and wear

and replace the desmodromic control rod if nec-
essary.
Check the desmodromic segment «3» for damage
and wear and replace it if necessary.
Check the desmodromic bearing «4» for damage
and cracks and replace it if necessary.

Checking the forks

NOTE
THE FOLLOWING PROCEDURE IS VALID FOR ALL GEARBOX FORKS.
• Check the transmission fork cam roller
«1» and the transmission fork tooth
«2» for damage, deformation and
wear.
• Replace the transmission fork if nec-
essary.

ENG - 91
Engine GRISO 1100

• Check the transmission fork move-

ment and if it is not regular, replace the
transmission forks.

See also
Disassembling the gearbox

Fitting the primary shaft

NOTE
TO REFIT, FOLLOW THE SAME INSTRUCTIONS AS FOR REMOVAL BUT IN REVERSE ORDER.
REMEMBER TO REPLACE ALL SEALING RINGS, CIRCLIPS AND SAFETY RINGS PREVIOUSLY
REMOVED.
See also
Removing the
primary shaft

Fitting the secondary shaft

NOTE
TO REFIT, FOLLOW THE SAME INSTRUCTIONS AS FOR REMOVAL BUT IN REVERSE ORDER.
REMEMBER TO REPLACE ALL SEALING RINGS, CIRCLIPS AND SAFETY RINGS PREVIOUSLY
REMOVED.
See also
Removing the
secondary shaft

Assembling the clutch shaft

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

Assembling the gearbox

NOTE
TO REFIT, FOLLOW THE SAME INSTRUCTIONS AS FOR REMOVAL BUT IN REVERSE ORDER.
REMEMBER TO REPLACE ALL SEALING RINGS, CIRCLIPS AND SAFETY RINGS PREVIOUSLY
REMOVED.
See also
Disassembling the gearbox

ENG - 92
GRISO 1100 Engine

Flywheel

Removing the flywheel

• Remove the clutch.

• Position the locking tool on the flywheel
and loosen the six flywheel fixing
screws operating diagonally and in
stages.
• Remove the locking tool.

Specific tooling
12.91.18.01 Tool to lock the flywheel and the
starting ring gear
• Remove the flywheel.

See also
Disassembling the
clutch

Checking

• Check that the flywheel surface that contacts the plate is not scratched.
• Check that the contact faces on the crankshaft are not distorted; if they are, replace the
flywheel.

ENG - 93
Engine GRISO 1100

Installing the flywheel

• Position the flywheel.

NOTE
RESPECT THE FLYWHEEL POSITIONING REFERENCES.
CAUTION
THE SCREWS MUST BE REPLACED WITH NEW ONES AT
THE FOLLOWING REFITTING AS THEY ARE SUBJECT TO
HIGH LOADS AND STRESS.

• Position the locking tool on the flywheel

and tighten the six flywheel sealing
screws operating diagonally and in
stages.
• Fit the clutch.

Specific tooling
12.91.18.01 Tool to lock the flywheel and the
starting ring gear

See also
Assembling the
clutch

Generator

Removing the generator

• Unscrew and remove the six screws

and collect the bushings.

ENG - 94
GRISO 1100 Engine

• Remove the cover.

• Unscrew and remove the eight screws.

• Undo and remove the two screws.

• Unscrew the nut and collect the screw.

ENG - 95
Engine GRISO 1100

• Loosen the screw.

• Loosen the nut and undo the set screw

so that the alternator slides down.

• Completely loosen and remove the

screw.

• Remove the belt and the alternator with

pulley.

ENG - 96
GRISO 1100 Engine

• Using a compressed air gun, unscrew

and remove the nut and collect the
spacer.
• Remove the lower pulley.

• Undo and remove the two screws.

• Remove the alternator frame.

• Remove the sealing ring if necessary.

Tensioning the belt

• Remove both fuel tank side fairings.

• Remove the right exhaust manifold.
• Remove the control unit.
• Unscrew and remove the fixing screw
of the engine oil scavenge reservoir.

ENG - 97
Engine GRISO 1100

• Unscrew and remove the spacer.

• Unscrew and remove the five fixing

screws of the timing system cover.
• Remove the timing system cover.
• Loosen the set screw lock nut.

• Using the belt tensioning tool (code

06.94.86.00), tension the belt to the
prescribed torque.
• Screw the set screw.
• Tighten the lock nut.

Specific tooling
06.94.86.00 belt tensioning tool

Installing the generator

• If the sealing ring has been previously

removed, replace it using the punch of
the timing system cover sealing ring.

Specific tooling
05.92.72.30 Timing system cover sealing ring
punch

ENG - 98
GRISO 1100 Engine

• Replace the gasket and place the al-

ternator frame using the front cover in-
sertion cone.
• Remove the insertion cone afterwards.

Specific tooling
05.91.17.30 Front cover insertion cone

• Tighten the two screws.

• Tighten the eight lower screws.

• Operating diagonally and in stages,
tighten the ten fixing screws on the al-
ternator fitting.

• Position the lower pulley and the

spacer.
• Tighten the nut to the prescribed tor-
que.

ENG - 99
Engine GRISO 1100

• Position the alternator and the timing

system belt.

• Position the screw and pre-tighten it.

• Position the screw and tighten the nut.

• Using the belt tensioning tool (code

06.94.86.00), tension the belt to the
prescribed torque and screw the set
screw.
• Remove the belt tensioning tool.
• Lock the set screw in position by
screwing the lock nut.

Specific tooling
06.94.86.00 belt tensioning tool

ENG - 100
GRISO 1100 Engine

• Tighten the alternator fixing screws.

• Tighten the four screws, operating di-

agonally and in stages.

• Position the timing system cover.

• Tighten the five screws, operating in
oblique direction and in stages.

Starter motor

Removing the starter motor

• Undo and remove the two screws and

collect the washers.

ENG - 101
Engine GRISO 1100

• Slide off the starter motor.

Clutch side

Disassembling the clutch

• Remove the gearbox from the engine.

• Use the locking tool and the clutch
spring compression tool on the fly-
wheel.

Specific tooling
30.90.65.10 Tool for clutch fitting
12.91.18.01 Tool to lock the flywheel and the
starting ring gear
• Undo and remove the eight sealing
screws from the sprocket gear on the
engine flywheel.

• Remove the start-up sprocket gear.

ENG - 102
GRISO 1100 Engine

Extract from the inside of the engine flywheel:

• the clutch plate.

• The intermediate plate.

• The second clutch plate.

• The pressure plate disc cover.

ENG - 103
Engine GRISO 1100

• The pressure plate disc with springs.

Checking the clutch plates

Driven plates
Check that the supporting surfaces with the driven plates are perfectly smooth and even and that the
external toothing that works inside the flywheel is not damaged, otherwise, replace the plate.
Crown gear for start-up
Check that the supporting surface with the driven plate is perfectly smooth and even.
Also check that the toothing where the starter motor pinion works is not chipped or scratched; otherwise,
replace it.

Checking the clutch housing

Check that the teeth do not show any marks on the plate faying areas and that the toothing inside the
clutch bell is in good conditions.

Checking the pusher plate

Pressure plate
Check that the plate does not show signs of wear on the opening where the control cap works, and that
the supporting surfaces with the driven plate are perfectly even.

Checking the springs

Check that the springs are still flexible and are not
deformed:

• Springs compressed at 22 mm (0.8661

in) must bear a load of 11.25 ÷ 11.70
kg (24.80 ÷ 25.79 pounds);
• Springs compressed at 20 mm (0.7874
in) must bear a load of 14.75 ÷ 15.30
kg (32.52 ÷ 33.73 pounds).

ENG - 104
GRISO 1100 Engine

Assembling the clutch

Insert the components in the clutch bell in the fol-

lowing order:

• the pressure plate with springs.

• Make sure that the reference marked

on the pressure plate tooth is aligned
with the reference on the flywheel.

• Use the locking tool and the clutch

spring compression tool on the fly-
wheel.

Specific tooling
30.90.65.10 Tool for clutch fitting
12.91.18.01 Tool to lock the flywheel and the
starting ring gear

ENG - 105
Engine GRISO 1100

• Remove the locking tool.

• Fit the clutch disc.

Specific tooling
12.91.18.01 Tool to lock the flywheel and the
starting ring gear

• The intermediate disc.

• The clutch disc.

• Place the crown gear aligning its refer-

ence with that on the flywheel.

ENG - 106
GRISO 1100 Engine

• Tighten the eight screws sealing the

crown gear to the flywheel to the pre-
scribed torque
• Remove the special tool for clutch
spring compression.

Specific tooling
30.90.65.10 Tool for clutch fitting

• Insert the pressure plate disc cover.

• Install the gearbox unit.

Head and timing

Removing the head cover

NOTE
THE FOLLOWING OPERATIONS REFER TO REMOVING ONLY ONE COVER BUT APPLY TO
BOTH COVERS.
• Unscrew and remove the eight screws
and collect the bushings.

ENG - 107
Engine GRISO 1100

• Remove the head cover and collect the

gasket.

Removing the cylinder head

• Remove the rocker rods.

• Unscrew and remove the outer spark
plug.

• Loosen the nut and disconnect the

pipes that deliver oil to the head.

• Unscrew and remove the threaded

cap.

ENG - 108
GRISO 1100 Engine

• Unscrew and remove the joint of the

pipe that delivers oil to the head and
collect the washer.

• Using the suitable special tool, un-

screw and remove the inner spark
plug.

Specific tooling
05.90.19.30 Inner spark plug removal

• Undo and remove the two screws and

collect the two washers.

ENG - 109
Engine GRISO 1100

• Slightly detach the cylinder head and

remove the four O-rings.

• Remove the head and collect the gas-

ket.

Cylinder head

Removing the rocker arms

NOTE
THE FOLLOWING OPERATIONS REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH
HEADS.
• Remove the head cover.

• Rotate the crankshaft to TDC position in com-

bustion phase (closed valves) for the left cylinder.
• Unscrew and remove the two screws.

ENG - 110
GRISO 1100 Engine

• Remove the rocking lever shafts.

• Remove the rocking levers and collect the three

washers.

See also
Removing the
head cover

Removing the valves

• Remove the head.

• Place the special tool on the upper cap
and at the centre of the head of the
valve to be removed.

Specific tooling
10.90.72.00 Tool for valve removal and refitting

• Tighten the tool screw until fitted, and

then hit the tool head (where the upper
retainer works) with a mallet so that the
two cotters (1) get detached from the
upper retainer (2).
• Once the two cotters (1) are detached,
screw these cotters until they can be

ENG - 111
Engine GRISO 1100

slid off the valve seats; unscrew the

tool and remove it from the head.
• Remove the upper retainer (2).
• Remove the internal spring (3).
• Remove the external spring (4).
• Remove the lower retainer (5) and the
shimming washers if necessary.
• Remove the valve (6) from inside the
head.

Checking the valve guides

Use a punch to extract the valve guides from the
heads.
The valve guides should be replaced only if the
clearance between them and the stem cannot be
eliminated by simply replacing the valves.
To refit the valve guides on the head, follow this
procedure:

• Heat the head in an oven at approxi-

mately 60°C (140°F).
• Lubricate the valve guide.
• Fit the circlips.
• Press a punch with the valve guides.
• Use a reamer to bore the holes the
valve stems slide through so that the
inside diameter is at the prescribed val-
ue. The interference between the seat
on the head and the valve guide must
be 0.046 - 0.075 mm (0.0018 - 0.0030
in)

VALVE AND GUIDES COUPLING DATA

CHART (INLET)
Specification Desc./Quantity
Valve guide inside diameter 8.000 ÷ 8.022 (0.3150 ÷
mm (in) 0.3158)
Valve stem diameter 7.972 ÷ 7.987 (0.3139 ÷
0.3145)
Fitting clearance mm (in) 0.013 ÷ 0.050 (0.0005 ÷
0.0020)

ENG - 112
GRISO 1100 Engine

VALVE AND GUIDES COUPLING DATA

CHART (OUTLET)
Specification Desc./Quantity
Valve guide inside diameter 8.005 ÷ 8.022 (0.3152 ÷
mm (in) 0.3158)
Valve stem diameter mm (in) 7.965 ÷ 7.980 (0.3136 ÷
0.3142)
Fitting clearance mm (in) 0.025 ÷ 0.057 (0.0010 ÷
0.0022)

Checking the cylinder head

Check that:

• The planes of contact with the cover and with the cylinder are not scored or damaged so as
to compromise a perfect seal.
• Check that the clearance between the valve guide holes and valve stanchions is within the
prescribed limits.
• Check the status of the valve seats.

The valve seats should be reamed with a mill. The

seat inclination angle is 45° +/- 5'. After milling, it
is necessary to grind them to ensure a good cou-
pling and a perfect sealing between the ring nuts
and the valve heads.

Installing the valves

NOTE
THE FOLLOWING OPERATIONS REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH
HEADS.

ENG - 113
Engine GRISO 1100

• Place the valve (6) inside the head.

• Place the lower retainer (5) and the
shimming washers.
• Place the external spring (4).
• Place the internal spring (3).
• Insert the upper retainer (2).
• Place the two cotters (1) on the seats
on the valves.
• Compressing the spring with the spe-
cial valve tool, install the valve cotters.

Specific tooling
10.90.72.00 Tool for valve removal and refitting
NOTE
UPON REFITTING, PLACE THE O-RING CORRECTLY ON
THE VALVE.

• Remove the special tool

ENG - 114
GRISO 1100 Engine

Installing the rocker arms

CAUTION
UPON REFITTING, ALWAYS REPLACE THE O-RINGS

CAUTION
UPON REFITTING, DO NOT INVERT THE POSITION OF
THE ROCKING LEVER SUPPORTS SO AS NOT TO COM-
PROMISE LUBRICATION.
CAUTION
THE NEW LUBRICATION SYSTEM IS VALID FROM EN-
GINE NUMBER KS13770 ON.

• Install the rocking lever rods if they

have been previously removed.
• Install the rocking lever support and re-
place the four O-rings.

• Place the four washers and screw the

four nuts.

ENG - 115
Engine GRISO 1100

• Place the six washers and install the

rocking levers.

• Insert the rocking lever shafts.

• Rotate the crankshaft to TDC position

in combustion phase (closed valves)
for the left cylinder.
• Tighten the two screws.

See also
Installing the rods

Timing

ENG - 116
GRISO 1100 Engine

Chain removal

• Remove the engine assembly.

• Remove the alternator.
• Clearly indicate the distribution timing
marks that should be restored at the
next refitting (left cylinder TDC).

• Using the adequate tool, lock the igni-

tion crown.

Specific tooling
12.91.18.01 Tool to lock the flywheel and the
starting ring gear

• Unscrew the central sealing nut of the

camshaft gear and collect the washer.

• Remove the cotter.

ENG - 117
Engine GRISO 1100

• Unscrew and remove the central seal-

ing nut of the timing system control
gear on the crankshaft and collect the
washer.

• Unscrew and remove the oil pump gear

nut and collect the washer.

• Remove the chain tensioner and col-

lect the spring.
• Slide off the three gears together with
the chain.
CAUTION
BE CAREFUL WITH THE OIL PUMP PULLING COTTER.

See also
Removing the engine from the vehicle

Removing the rods

• Remove the rocking levers.

• Unscrew and remove the four nuts and
collect their washers.

ENG - 118
GRISO 1100 Engine

• Remove the rocking lever support.

• Remove the two rocking lever rods

See also
Removing the rocker arms

Removing the tappets

• Remove the engine assembly.

• Remove both heads.
• Slide off and remove the tappets from
their seat on both sides.

See also
Removing the engine from the vehicle

ENG - 119
Engine GRISO 1100

Removing the phonic wheel

• Remove the timing chain.

• Slide off the tone wheel and collect the
plug.

See also

Chain removal

Removing the camshaft

• Remove the timing chain.

• Remove the tone wheel.
• Remove the tappets.
• Remove the rods.

• Unscrew and remove the three screws

and collect the washers.

• Remove the flange.

ENG - 120
GRISO 1100 Engine

• Remove the camshaft.

Installing the camshaft

NOTE
FOR TIMING SYSTEM REFITTING, IT IS NECESSARY TO HEAT THE ENGINE WITH A SUITABLE
HEATER IN ORDER TO INSERT THE CAMSHAFT CORRECTLY AND WITHOUT DAMAGING IT.
Follow the camshaft removal instructions but in reverse order.

Installing the rods

• Install the head if it has been previously

removed.
• Replace the four O-rings.

• Install the two rocking lever rods.

Installing the chain

For the installation of the three gears and of the timing chain carry out the operations indicated in section
"Timing".

ENG - 121
Engine GRISO 1100

Cam timing

• On the crankcase, fit the crankshaft

and the camshaft.
• Fit the cylinders and the heads.
• Fit the rods.
• Do not fit the rocking levers before car-
rying out engine timing so as not to
damage the valves during the rotation
of the camshaft.
• Turn the crankshaft until the left cylin-
der piston reaches the top dead centre
(TDC).
• Fit the flywheel on the crankshaft align-
ing the stamp arrow on the flywheel
with the fixed reference on the crank-
case.

• Position the locking tool on the flywheel

and tighten the six flywheel sealing
screws operating diagonally and in
stages.
• Fit the clutch.

Specific tooling
12.91.18.01 Tool to lock the flywheel and the
starting ring gear

• Fit the plug on the camshaft.

• Introduce the tone wheel with the
smooth side facing outward.

ENG - 122
GRISO 1100 Engine

• Place the shim washer adequately so

that the timing chain do not wear out
the crankcase.
• Fit the three timing system gears and
the chain aligning the references on
the camshaft and crankshaft gears.

• Introduce the belleville spring and the

nut to fasten the camshaft gear.

• Introduce the washer and the nut to

fasten the crankshaft gear.

ENG - 123
Engine GRISO 1100

• Turn the oil pump shaft and introduce

the gear pulling woodruff key.

• Introduce the chain tensioner.

• Remove the flywheel locking tool.

• Check the crankshaft rotation.
• Fit the rocking levers.

Specific tooling
12.91.18.01 Tool to lock the flywheel and the starting ring gear

Timing

To check distribution timing, follow these instruc-

tions:

• Obtain a clearance between rocking

levers and valves equal to 1.5 mm
(0.059 in);
• Place the hub for graduated dial and
the relative graduated dial on the
crankshaft slot, inserting the spacer
and fixing it to the shaft with the nut.

Specific tooling
981006 Graduated dial hub
19.92.96.00 Graduated dial to control ignition
timing

ENG - 124
GRISO 1100 Engine

• With a screw, fasten the specific arrow

to the threaded hole to the left of the
crankcase.

Specific tooling
17.94.75.60 Arrow to control ignition timing

• Fit the dial gauge support and then the

gauge itself on the left outer spark plug
hole.

• Rotate the crankshaft until the left cyl-

inder piston is actually at the top dead
centre (with valves closed).
• Reset the dial gauge and make sure
the references (on the timing system
gears and the engine pinion) are per-
fectly aligned, so that looking through
the checking hole on the gearbox, the
reference line marked 'S' is perfectly
aligned with the reference marked at
the centre of the hole.
• Align the arrow point with the TDC zero
on the graduated dial.

ENG - 125
Engine GRISO 1100

• Observing the timing system diagram,

check timing considering that:

A - intake start opens 22° before TDC

B - exhaust end closes 24° after TDC
C - exhaust start opens 52° before BDC
D - intake end closes 54° after BDC

• Screw the dial gauge support and then

the gauge itself on the right cylinder
outer spark plug hole.
• With a screw, fix the arrow to the threa-
ded hole to the right of the crankcase.
• Turn the disc clockwise until the refer-
ence marked with letter 'D' is aligned
with the reference at the centre of the
checking hole on the gearbox (valves
closed).
• Repeat the operations described
above for the left cylinder.

• After the check and if everything is correct, operate as follows to restore the operation clear-
ance between rocking levers and valves (intake 0.10 mm (0.0039 in), outlet 0.15 mm (0.0059
in).
• Remove the graduated dial hub, the graduated dial, the arrow, the dial gauge support and
the gauge itself.

ENG - 126
GRISO 1100 Engine

• Refit the spark plugs and finish the refit.

Specific tooling
981006 Graduated dial hub
19.92.96.00 Graduated dial to control ignition timing
17.94.75.60 Arrow to control ignition timing

Measuring air gap

• Undo and remove the two screws and

remove the sensor.

• Insert a suitable plain washer on the

sensor and note its thickness.

ENG - 127
Engine GRISO 1100

• Place the sensor on the timing system

cover and cause it to make contact with
the tone wheel.

• Measure the clearance between the

fixing plate and the cover with a feeler
gauge. Subtract the plain washer value
from this measurement to obtain the
clearance between the sensor and the
tone wheel.

• Remove the washer and fit the sensor after applying adequate sealing paste on the fixing
plate, then tighten the screws to the prescribed torque.

Cylinder-piston assembly

Removing the cylinder

NOTE
THE OPERATIONS DESCRIBED BELOW REFER TO ONE HEAD REMOVING ONLY BUT APPLY
TO BOTH HEADS.
• Remove the head.
• Slide off the gasket.

ENG - 128
GRISO 1100 Engine

• Slide off the cylinder from the stud

bolts, paying attention not to damage
the piston.

See also
Removing the
cylinder head

Disassembling the piston

NOTE
THE OPERATIONS DESCRIBED BELOW REFER TO ONE HEAD REMOVING ONLY BUT APPLY
TO BOTH HEADS.
• Remove the cylinder.
• Cover the crankcase opening with a
clean cloth.
• Release the snap ring.

• Remove the pin.

ENG - 129
Engine GRISO 1100

• Mark the piston crown on the exhaust

side so as to remember the refitting po-
sition.
• Remove the piston.

Fitting the piston

NOTE
THE OPERATIONS DESCRIBED BELOW REFER TO REMOVING ONLY ONE HEAD BUT APPLY
TO BOTH HEADS.
• Fit the piston.
NOTE
CHECK THE ORIENTATION OF THE PISTON ACCORDING
TO THE REFERENCES AT THE TOP. DO NOT ASSEMBLE
PISTONS AND CYLINDERS OF DIFFERENT SELECTOR
TYPES.

• Insert the pin.

• Insert the pin clip.

ENG - 130
GRISO 1100 Engine

Installing the cylinder

• Fit the piston.

• Remove the cloth used to prevent foreign bodies coming into the crankcase.
• Turn the rings so that the junction ends are 120 degrees from each other.
• Lubricate piston and cylinder.
• Using a specific tool for piston ring clamps, place the cylinder.
CAUTION
DURING THIS OPERATION, PAY ATTENTION NOT TO DAMAGE THE PISTON.
Specific tooling
05.92.80.30 Piston ring clamp

• Remove the piston ring clamp tool and

finish positioning the cylinder.

Specific tooling
05.92.80.30 Piston ring clamp

CAUTION
UPON REFITTING DO NOT INVERT THE POSITION OF THE
CYLINDER GASKET SO AS NOT TO COMPROMISE LU-
BRICATION.
CAUTION
THE NEW LUBRICATION SYSTEM IS VALID FROM EN-
GINE NUMBER KS13770 ON.

• Place the gasket on the cylinder base.

• Fit the head.

See also
Fitting the piston

ENG - 131
Engine GRISO 1100

Installing the
cylinder head

Installing the cylinder head

• Fit the valves if they have been previ-

ously removed.
• Replace the gasket between head and
cylinder.
• Fit the head.

• Place the two washers and tighten the

two screws.

• Using the suitable special tool, screw

the inner spark plug.

Specific tooling
05.90.19.30 Inner spark plug removal

ENG - 132
GRISO 1100 Engine

• Insert the washer and screw the joint of

the pipe that delivers oil to the head .

• Screw the threaded cap.

• Connect the pipes that deliver oil to the

head and screw the nut.

• Install the outer spark plug.

ENG - 133
Engine GRISO 1100

• Replace the gasket and install the

head cover.

See also
Installing the
head cover

Installing the head cover

• Replace the gasket and fit the head

cover.
• Place the bushings and cross tighten
the eight screws.

Crankcase - crankshaft

Removing the crankshaft

• Remove the connecting rods.

ENG - 134
GRISO 1100 Engine

• Undo and remove the eight fixing

screws and collect the washers.

• Hold the crankshaft during flange re-

moval.
• Using the suitable special tool, remove
the crankshaft flange.
• Remove the sealing ring from the
flange, if necessary.

Specific tooling
12.91.36.00 Tool to remove the flywheel-side
flange
• Remove the crankshaft afterwards.

See also
Disassembling the connecting rod

Disassembling the connecting rod

• Remove the heads.

• Remove the cylinders and the pistons.
• Remove the clutch.
• Remove the flywheel.
• Remove the timing system.
• Remove the oil sump.

ENG - 135
Engine GRISO 1100

• Loosen the coupling screws 'A' from

inside the crankcase and remove the
connecting rods 'B'.
See also
Removing the flywheel
Disassembling the piston
Removing the
cylinder
Removing the
cylinder head

Inspecting the crankshaft components

Check the surfaces of the main journals; if they are scored or oval-shaped, reface them (observing the
undersize charts), and replace the flanges and the main journals.

FITTING CLEARANCES
Specification Desc./Quantity
Between the bearing and the main journal on the timing system 0.028 ÷ 0.060 mm (0.00110 ÷ 0.00236 in);
side
Between the bearing and the main journal on the flywheel side 0.040 ÷ 0.075 mm (0.00157 ÷ 0.00295 in)
Between the bearing and the connecting rod pin 0.022 ÷ 0.064 mm (0.00087 ÷ 0.00252 in)

MAIN JOURNAL DIAMETER ON THE TIMING SYSTEM SIDE (A)

Specification Desc./Quantity
Main journal regular production 37.975 mm (1.49507 inch)
37.959 mm (1.49444 inch)

CRANKPIN DIAMETER (B)

Specification Desc./Quantity
Regular production 44.008 ÷ 44.020 mm - (1.73259 ÷ 1.73307 in)
'Blue' bushing half-shell regular production 44.008 ÷ 44.014 mm (1.73259 ÷ 1.73283 in)
'Red' bushing half-shell regular production 44.014 ÷ 44.020 mm (1.73283 ÷ 1.73307 in)

FLYWHEEL SIDE MAIN JOURNAL DIAMETER (C)

Specification Desc./Quantity
Regular production 52.970 mm (2.08542 inch)
53.951 mm (2.12405 inch)

Checking the connecting rod

CONNECTING RODS

ENG - 136
GRISO 1100 Engine

When examining the connecting rods, check that:

• Bushings are in good conditions, their clearance and the pins;

• Shaft parallelism;
• Connecting rod bearings.

These are thin shell bearings, anti-friction alloy that does not allow for any adaptation; replace them
immediately if seizing or wear marks are found.
Upon replacing the bearings it may be necessary to ream the crankshaft pin.
Before reaming the crankpin, measure the pin diameter comparing it with the maximum wear allowed,
as indicated in the figure; this defines what kind of undersizing the bearing should have and to which
diameter the pin should be reamed.
Checking shaft parallelism
Check shafts for squaring before fitting them.
It is therefore necessary to check that the head holes and the rod small end are parallel and on the
same plane.
The maximum parallelism and plane error of the two shafts of the head and rod small end, measured
at 200 mm (7.873 inch) should be +/- 0.10 mm (0.00393 inch).

CONNECTING ROD BEARING THICKNESS

Specification Desc./Quantity
Connecting rod bearing regular (production) 1.535 - 1.544 mm (0.06043 - 0.06079 in)
Regular 'Blue' connecting rod bearing (production) 1.539 - 1.544 mm (0.06059 - 0.06079 in)
Regular 'Red' connecting rod bearing (production) 1.535 - 1.540 mm (0.06043 - 0.06063 in)

ENG - 137
Engine GRISO 1100

CRANKPIN DIAMETER (B)

Specification Desc./Quantity
Regular production 44.008 ÷ 44.020 mm - (1.73259 ÷ 1.73307 in)
'Blue' bushing half-shell regular production 44.008 ÷ 44.014 mm (1.73259 ÷ 1.73283 in)
'Red' bushing half-shell regular production 44.014 ÷ 44.020 mm (1.73283 ÷ 1.73307 in)

PIN-BUSHING COUPLING DATA

Specification Desc./Quantity
fitted and machined bushing inside Ø mm (inch) 22.007 mm (0.86641 inch) - 22.020 mm (0.86692 inch)
pin Ø mm (inch) 21.994 mm (0.86590 inch) - 21.998 mm (0.86606 inch)
Clearance between pin and bushing mm (inch) 0.009 ÷ 0.026 mm (0.000354 ÷ 0.001024 inch)

Assembling the connecting rod

• The references on the connecting rods

should be facing the flywheel.
• Do not interchange left and right con-
necting rods.

• Place the connecting rods and the

caps (B) on the crankshaft and fasten
them with new screws (A).
• Remember these recommendations:

• The screws fixing the connecting rods to the crankshaft must be replaced with new ones at
the following refitting as they are subject to high loads and stress;
• The fitting clearance between bearing and connecting rod pin is 0.028 mm (0.0011 inch)
minimum and 0.052 mm (0.0020 inch) maximum;
• The clearance between the shim washers of the connecting rod and those of the crankshaft
is comprised between 0.30 mm (0.01181 in) and 0.50 mm (0.01968 in);
• Lock the screws (A) on the caps (B) with a torque wrench at the prescribed torque.

Installing the crankshaft

• Use the sealing ring fitting tool on the flywheel-side flange to fit the sealing ring on the flange.

Specific tooling

ENG - 138
GRISO 1100 Engine

19.92.71.00 Tool to fit the seal ring on the flywheel-side flange

• Fit a new gasket between the crankcase and the crankshaft flange, flywheel side.

• Introduce the crankshaft.

• Place the flywheel side crankshaft sup-
port flange, taking into account the fit-
ting order indicated by the holes.

Specific tooling
19.92.71.00 Tool to fit the seal ring on the fly-
wheel-side flange

• Apply Teflon tape on the two lower fix-

ing screws at the back in order to pre-
vent oil leaks.
• Screw the eight flange screws on the
flywheel side proceeding diagonally.

Lubrication

Oil pump

Removing

• Drain all the engine oil.

• Remove the alternator.
• Remove the timing system.
• Remove the shim washer.

ENG - 139
Engine GRISO 1100

• Unscrew and remove the three screws

fixing the oil pump.
• Remove the oil pump.

Installing

• Fit the oil pump.

• Tighten the three oil pump fixing
screws.

• Place the shim washer adequately so

that the timing chain do not wear out
the crankcase.
• Fit the timing system.
• Fit the alternator.
• Top-up with engine oil.

Removing the oil sump

NOTE
TO REMOVE THE OIL SUMP, PLACE A SUITABLE CONTAINER UNDER IT TO COLLECT THE
USED OIL AND DRAIN OUT ALL OIL.
CAUTION
THE NEW LUBRICATION SYSTEM IS VALID FROM ENGINE NUMBER KS13770 ON.
• If necessary, the filter can be removed with the suitable special tool.

Specific tooling
01.92.91.00 Wrench for removing the cover on sump and filter

ENG - 140
GRISO 1100 Engine

• Unscrew and remove the oil level plug

and collect the O-Ring.

• Undo and remove the fourteen screws

fixing the oil sump to the engine crank-
case.

• Unscrew and remove the four screws

and remove the engine oil sump cover.

• Unscrew and remove the two screws.

ENG - 141
Engine GRISO 1100

• Unscrew and remove the two screws.

• Remove the mesh filter and collect the
gasket.

• Remove the black flange and collect

the gasket.

• Unscrew and remove the plug.

• Remove the thermostatic valve.

ENG - 142
GRISO 1100 Engine

• Unscrew and remove the pressure re-

lief valve plug.
• Remove the pressure relief valve com-
ponents

Refitting the oil sump

• Place the pressure relief valve compo-

nents correctly.
• Screw the pressure relief valve plug.

ENG - 143
Engine GRISO 1100

• In case of overpressure, the engine oil

goes back into the oil sump through the
hole indicated in the picture.

• Place the thermostatic valve.

CHECK THAT THE ENGINE OIL PASSAGE HOLE IS NOT

CLOGGED.

• Tighten the thermostatic valve plug.

• Place a new gasket and refit the black

flange.

ENG - 144
GRISO 1100 Engine

• Place a new gasket and refit the mesh

filter tightening the two screws.

• Tighten the two screws.

• Place the oil sump cover.

• Tighten the four screws.
• Refit the oil sump on the base.
• Fill engine oil up to the correct level.

Blow-by

• Loosen the oil return pipe sealing joint

and remove the oil return pipe from the
crankcase.

ENG - 145
Engine GRISO 1100

• Remove the clamp.

• Release the two straps retaining the oil

breather pipe.

• Remove the two oil breather pipes.

• Unscrew and remove the oil return pipe

positioning screw.
• Release the oil return pipe

ENG - 146
GRISO 1100 Engine

• Remove the complete blow-by system.

ENG - 147
INDEX OF TOPICS

POWER SUPPLY P SUPP

GRISO 1100 Power supply

Circuit diagram

Key:
1 Complete fuel pump assembly
2 Flange screw
3 Union
4 Clamp
5 Fuel pipe
6. Three-way joint
7 Clamp
8 Pipe

Injection

P SUPP - 149
Power supply GRISO 1100

Diagram

Key:
1 Control unit
2 Ignition switch
3 Battery
4 Fuel pump
5 Coils
6 Instrument panel
7 Air temperature sensor
8. Throttle valve position sensor
9 Injectors
10 Engine temperature sensor
11 Crankshaft position sensor
12. Side stand

P SUPP - 150
GRISO 1100 Power supply

13 Lambda probe
14 Fall sensor

Cylinders synchronisation

• With engine off, connect the Navigator

tool to the diagnosis connector and to
the vehicle battery.

• Turn on the scanner.

• Screw the joints connecting the vacuometer pipes on the inlet pipe holes.
• Connect the vacuometer pipes to the relative joints.
• Set the key to ON.
• Make sure there are no errors in the control unit; otherwise, solve them and repeat the
procedure.

• Make sure the left throttle is fully in.

DO NOT TOUCH THE THROTTLE ABUTMENT SCREW OR

THE THROTTLE BODY MUST BE REPLACED. CHECK
THAT THE THROTTLE RETURN CABLE IS NOT TAUT.

• The Axone should display the adjustable parameters screen page.

• Autodetect the throttle position.

P SUPP - 151
Power supply GRISO 1100

• Turn the key to "OFF" and leave it for

at least 30 seconds.
• Turn the key back to "ON" and restore
the Axone session.
• Check that the "Throttle" value reading
is 4.7 +/- 0.2°. If the value is incorrect,
replace the control unit and repeat the
procedure from the start.
• Completely close the two by-pass
screws on the throttle bodies.
• Start the engine.
• Take the engine to the prescribe tem-
perature: 60 °C (140 °F).
• Make the engine rev at 2000/3000 rpm
and with the vacuometer check that the
difference between the two pressures
is 1 cm Hg (1.33 kPa) maximum.

If this condition is detected:

• take the engine back to idle and check

the depression values so that they are
aligned between the two cylinders.
Otherwise, open only the screw with
higher depression, using the by-pass
screws, to compensate.

If there is a larger difference:

• act on the set screw of the throttle body

connecting rod to reduce the pressure
difference in the two pipes.
• Repeat the procedure "Throttle posi-
tion self-acquisition" as explained
above.
• Take the engine back to idle and check
the depression values so that they are
aligned between the two cylinders.
• Otherwise, open only the screw with
higher depression, using the by-pass
screws, to compensate.

P SUPP - 152
GRISO 1100 Power supply

Recovery function

If the signal of the following sensors is interrupted, the control unit determines some values to keep the
engine running or it uses a different parameter. The instrument panel and the Axone also signal the
problem.

RECOVERY FUNCTION
Specification Desc./Quantity
air temperature 25 °C (77 °F)
engine temperature 30 °C (86 °F)
with linear increase from the air temperature at ignition
barometric pressure 1010 hPa
throttle valve potentiometer 2.9° at idle, otherwise variable.
idle motor fixed value variable depending on the vehicle

Using axone for injection system

Injection

Iso screen page

ISO
This screen page shows general data regarding
the control unit, for example software type, map-
ping, control unit programming date

ISO DISPLAY
Specification Desc./Quantity
Mapping -

P SUPP - 153
Power supply GRISO 1100

Engine parameter reading screen page

ENGINE PARAMETER READING

This screen page shows the parameters meas-
ured by the several sensors (engine revs, engine
temperature, etc.) or values set by the control unit
(injection time, ignition advance, etc.)

ENGINE PARAMETER READING SCREEN PAGE

Specification Desc./Quantity
Engine rpm Engine revolutions per minute: the minimum value is set by the
control unit cannot be adjusted
Injection time - ms
Ignition advance -°
Air temperature °C
Temperature of the air taken in by the engine, measured by the
sensor in the filter casing. This is not the temperature indicated
by the instrument panel
Engine temperature °C
Battery voltage V
Throttle Value corresponding to the throttle when closed (approximate
value between 4.5 and 4.9°) (left throttle supported by the end
of stroke screw). If a different value is read, it is necessary to
activate the parameter "Throttle positioner autodetection" and
obtain this value.
Atmospheric pressure 1015 mPa (approximate values)
The sensor is inside the instrument panel
Lambda probe 100 - 900 mV (approximate values)
Signal when energised that the control unit receives from the
lambda probe: inversely proportional to the presence of oxygen
Lambda integrator When the control unit uses the lambda probe signal (see the
'Lambda' parameter on the 'Device status' display) this value
should be close to 0%
Vehicle speed - km/h
Target engine revs 1150 rpm (approximate values)
Parameter valid at idle, setting depends especially on the en-
gine temperature: the control unit will try to keep the engine
running at this revs, acting on the ignition advance and the
Stepper motor
Stepper base 70 - 100 (approximate values)
Steps corresponding to the Stepper motor reference position
CL Stepper 70 - 150 (approximate values)
Steps set by the control unit for the Stepper motor. At idle, steps
so that the engine keeps the target engine revs set by the con-
trol unit
Stepper regulator Difference between current steps of motor at idle and those at
the reference position
Virtual throttle angle from Stepper 0°
With engine not at idle speed, this value indicates the throttle
degrees corresponding to the Stepper motor air flow

P SUPP - 154
GRISO 1100 Power supply

Device status screen page

DEVICE STATUS
This screen page shows the status (usually ON/
OFF) of the vehicle devices or the operation con-
dition of some vehicle systems (for example, lamb-
da probe functioning status).

DEVICE STATUS
Specification Desc./Quantity
Engine status ON/run/power-latch/stopped
operation conditions
Throttle position Released / pressed
indicates if the throttle potentiometer is open or closed
Stand Retracted / extended
indicates the position of the side stand (only with gear engaged)
Ignition Enabled / disabled
indicates if the control unit consents engine start-up
RUN / STOP switch Run / stop
indicates the position of the safety switch
Clutch No / Yes
indicates the clutch sensor status
Gear engaged No / Yes
indicates the gear sensor status
fall sensor Normal / Tip over
indicates the vehicle fall sensor status
Lambda Open loop / Closed loop
Indicates if the control unit is using (CLOSED) the lambda
probe signal to keep the stoichiometric combustion. At idle
CLOSED only if: Air T over 20°C (68°F) and engine T over 30°
C (86°F) and engine on for at least 2-3 minutes
Synchronisation Synchronised / Not synchronised
Indicates if the control unit detects the revolution sensor signal
correctly

Devices activation screen page

DEVICES ACTIVATION
This screen page is used to delete errors in the
control unit memory and to activate some systems
controlled by the control unit.

DEVICES ACTIVATION
Specification Desc./Quantity
Left coil operation for 2.5 m, 5 times

P SUPP - 155
Power supply GRISO 1100

Specification Desc./Quantity
Right coil operation for 2.5 m, 5 times
Left injector Operation for 4 m, 5 times
Right injector Operation for 4 m, 5 times
Error clearing By pressing the 'enter' button, the stored errors (MEM) become
part of the historical data (STO). In the next connection be-
tween the Navigator and the control unit, the historical errors
(STO) are no longer shown
Fuel pump Operation for 30''
Stepper control <span style="FONT-SIZE: 12pt; FONT-FAMILY: "Times New
Roman"; mso-fareast-font-family: "Times New Roman"; mso-
ansi-language: IT; mso-fareast-language: IT; mso-bidi-lan-
guage: AR-SA">For 4'' advancement command of 32 steps, for
the next 4'' retrocession command of 32 steps and so on for
30''

Errors display screen page

ERRORS DISPLAY
This screen page shows potential errors detected
in the vehicle (ATT) or stored in the control unit
(MEM) and it allows to check error clearing (STO).

ERRORS DISPLAY
Specification Desc./Quantity
Pressure sensor Possible short circuit in the earth lead, battery or open circuit:
recovery function noticeable for customer. Careful with the air
pressure sensor in the instrument panel
Air temperature Possible short circuit in the earth lead, battery or open circuit:
recovery function hardly noticeable for customer.
Engine temperature Possible short circuit in the earth lead, battery or open circuit:
recovery function.
Throttle actuator position sensor Possible short circuit in the earth lead, battery or open circuit:
recovery function noticeable for customer.
Lambda probe Possible short circuit on the earth lead, battery or open circuit
or plausibility: recovery function hardly noticeable for customer.
Left injector Possible short circuit in the earth lead, battery or open circuit.
If both injectors do not work, the engine does not work
Right injector Possible short circuit in the earth lead, battery or open circuit.
If both injectors do not work, the engine does not work
Fuel pump relay Possible short circuit in the earth lead, battery or open circuit:
the engine does not start.
Left coil Possible short circuit in the earth lead, battery or open circuit.
If both coils do not work, the engine does not work.
Right coil Possible short circuit in the earth lead, battery or open circuit.
If both coils do not work, the engine does not work.
Idle regulator Possible short circuit in the earth lead, battery or open circuit:
recovery function noticeable for the customer due to no idle
management
Battery voltage Battery voltage detected is too low (7V) or too high (16V) for a
certain period
Starter diagnosis Possible short circuit in the earth lead, battery or open circuit.
Engine revolution sensor Possible open circuit.
Lambda heater Possible short circuit in the earth lead, battery or lambda probe
heating circuit open.
SPEED SENSOR

P SUPP - 156
GRISO 1100 Power supply

Specification Desc./Quantity
CAN line diagnosis <span style="FONT-SIZE: 12pt; FONT-FAMILY: "Times New
Roman"; mso-fareast-font-family: "Times New Roman"; mso-
ansi-language: IT; mso-fareast-language: IT; mso-bidi-lan-
guage: AR-SA">Possible error on line CAN: short circuit or line
break or no signal or plausibility error detected.
RAM memory Possible internal control unit error. Also check the control unit
supply and earth connections
ROM memory Possible internal control unit error. Also check the control unit
supply and earth connections
Microprocessor Possible internal control unit error. Also check the control unit
supply and earth connections
Checksum EPROM Possible internal control unit error. Also check the control unit
supply and earth connections

Adjustable parameters screen page

ADJUSTABLE PARAMETERS
This screen page is used to adjust some control
unit parameters.

ADJUSTABLE PARAMETERS
Specification Desc./Quantity
Throttle positioner autodetection Allows the control unit to detect the closed throttle position: just
press the enter button

P SUPP - 157
INDEX OF TOPICS

SUSPENSIONS SUSP
GRISO 1100 Suspensions

Front

Removing the front wheel

• Working from both sides, undo and re-

move the two fixing screws from the
front brake callipers and remove them
from their seats.

• Hold the vehicle front part.

• Unscrew and remove the wheel axle
fixing nut and collect the sealing wash-
er.

• Working from both sides, loosen the

screws on the wheel bolt clamps.

• Tap the wheel axle slightly with a rub-

ber mallet so that the hole on the op-
posite side is exposed.

SUSP - 159
Suspensions GRISO 1100

• Remove the wheel axle by inserting a

screwdriver in the holes on the pin.
• During extraction, support the wheel
and then remove it.

• Collect the spacer from the front wheel

right side.

Front fork

SUSP - 160
GRISO 1100 Suspensions

Diagram

Key:
1 Locking ring
2 Spring preloading regulator
3 Spring preloading pusher
4 Sleeve upper cover
5 Washer
6 Slider
7 Complete pumping member
8 Centring bushing
9 Spring pressing pipe
10 Spring
11 Spring support washer
12 Lower collar

SUSP - 161
Suspensions GRISO 1100

13 Sleeve
14 Sliding bushing
15 Guide bushing
16 Stop washer
17 Gasket
18 Snap ring
19 Dust guard gasket
20 Wheel holder stem
21 Copper washer
22 Central screw
23 O-ring
24 O-ring

Adjustment

The standard front fork setting is adjusted to suit

most low and high speed riding conditions, wheth-
er the vehicle is partially or fully loaded. This set-
ting can also be customised based on vehicle use.
CAUTION
SPORTS SETTING MAY BE USED ONLY FOR OFFICIAL
COMPETITIONS TO BE CARRIED OUT ON TRACKS,
AWAY FROM NORMAL ROAD TRAFFIC AND WITH THE
AUTHORISATION OF THE RELEVANT AUTHORITIES.
IT IS STRICTLY FORBIDDEN TO USE SPORT SETTINGS
AND RIDE THE VEHICLE SO SET ON ROADS AND MO-
TORWAYS.

FOR ADJUSTMENT, ALWAYS START FROM THE MOST

RIGID SETTING (SET SCREWS (1 - 2) FULLY CLOCKWISE).
USE THE NOTCHES ON SET SCREWS (1 - 2) AS REFER-
ENCES TO ADJUST HYDRAULIC COMPRESSION AND RE-
BOUND DAMPING.
TURN THE SET SCREWS (1 - 2) GRADUALLY BY 1/8 OF A
TURN AT A TIME.

FRONT FORK ADJUSTMENT

Specification Desc./Quantity
Standard rebound damping adjustment, screw (1) Open (**) 1.25 turn from fully closed (*)
Hydraulic rebound damping adjustment for sports use, screw Open (**) 0.5 - 1 turn from fully closed (*)
(1)
Standard compression damping adjustment, screw (2) Open (**) (S) 1 turn from fully closed (*) (H)
Hydraulic compression damping adjustment for sports use, Open (**) (S) 0.5 - 1 turn from fully closed (*) (H)
screw (2)
Spring preloading, nut (3) Open (**) 4 - 5 protrusion notches from fully closed (*)
Stems (A) protrusion from top plate (excluding cover) (standard 4 protrusion notches
adjustment)

SUSP - 162
GRISO 1100 Suspensions

Specification Desc./Quantity
Take your vehicle only to a Moto Guzzi Official Dealer for this
type of adjustment.
Stems (A) protrusion from top plate (excluding cover) (sports 5 protrusion notches
use adjustment) Take your vehicle only to a Moto Guzzi Official Dealer for this
type of adjustment.

Removing the fork legs

• Remove the front mudguard.

• Support the fork stem and loosen the
screws on the upper and lower plates.
• Slide off the fork stem.

See also
Removing the
front wheel

Draining oil

• Lock the sleeve in a vice with the spe-

cific tool (code AP8140149).
• Set the minimum spring preloading.

Specific tooling
AP8140149 Protection for fitting operations

SUSP - 163
Suspensions GRISO 1100

• Unscrew the sleeve top cap.

• Lock the calliper mounting bracket in a

vice paying attention not to damage it.

• Fit the tool on the spring joint.

Specific tooling
AP8140147 Spacer tool

• Push the tool against the spring and

compress it. Fit the spacer of the tool
under the cartridge lock nut.

Specific tooling
AP8140148 Spacer-piston separating plate

SUSP - 164
GRISO 1100 Suspensions

• Loosen the cap by the key grip and by

making the lock nut turn.

• Remove the complete cap.

• Remove the spacer and the washer.

• Press down and force the spring to
compress. Remove the spacer.

SUSP - 165
Suspensions GRISO 1100

• Remove the spring joint.

• Drain off oil into a collecting container

and remove the spring.

Disassembling the fork

• After emptying the oil, fasten the cal-

liper mounting bracket of the fork stan-
chion in a vice.
• Position the washer and the lower
spacer.

SUSP - 166
GRISO 1100 Suspensions

• Unscrew the cartridge fixing screw on

the fork feet.
• Retrieve the centring bushing.

• Slide off the dust scraper from the

sleeve using a screwdriver as a lever.
• During this operation, pay attention not
to damage the sleeve rim.

• Remove the retainer ring.

• Take out the sleeve from the stem us-

ing the stem as a hammer puller.

SUSP - 167
Suspensions GRISO 1100

• From the stem remove the fixed fitted

bushing, the movable bushing, the ring
and the oil seal.

SUSP - 168
GRISO 1100 Suspensions

• Remove the ring and the dust guard.

See also
Draining oil

Checking the components

Stem
Check the sliding surface for scorings and/or scratches.
These scorings can be eliminated by rubbing them with wet sandpaper (grain 1).
If the scorings are deep, replace the stem.
Use a dial gauge to check that the stem bending is below the limit value.
If over the value, replace the stem.
CAUTION
A BENT STEM SHOULD NEVER BE STRAIGHTENED BECAUSE ITS STRUCTURE WOULD BE
WEAKENED AND USING THE VEHICLE MAY BECOME DANGEROUS.
Characteristic
Bending limit:
0.2 mm (0.00787 in)

Sleeve
Check that there are no damages and/or cracks; otherwise, replace it.
Spring
Check that the spring is in good conditions. Check that the spring length is within the limit value.
Replace the spring if its length does not fall within the limit values.
SPRING MINIMUM LENGTH WHEN UNLOADED: 284 mm (11.2 in)

Check that the following components are in good

conditions:

• sliding bushing;
• guide bushing;

SUSP - 169
Suspensions GRISO 1100

• piston.

If there are signs of excessive wear or damage, replace the affected component.
CAUTION
REMOVE ANY IMPURITY IN THE BUSHINGS, TAKING CARE NOT TO SCRATCH THEIR SUR-
FACE.
Replace the following components with new ones:

• gasket;
• dust guard gasket;
• the two O-rings on the regulator.

Reassembling the fork

• Lock the stem in a vice without dam-

aging the surface.
• Protect the bearing tube end with ad-
hesive tape.
• Lubricate the sliding edges with fork oil
or sealing grease.
• Fit on the slider the dust scraper, the
retainer ring and the seal ring.

SUSP - 170
GRISO 1100 Suspensions

• The sealing ring must be placed with

the stamped part facing the dust gaiter.

• Fit the ring, the movable bushing and,

after removing the tape, fit the fixed
bushing.

SUSP - 171
Suspensions GRISO 1100

• Fit the sleeve on the stem and set the

oil seal into position with the aid of the
specific tool.

Specific tooling
AP8140149 Protection for fitting operations

• Insert the retainer ring in its position.

SUSP - 172
GRISO 1100 Suspensions

• Fit the oil seal with the specific tool.

Specific tooling
AP8140149 Protection for fitting operations

• Fit the centring bushing on the car-

tridge and insert the whole assembly in
the fork.

• Tighten the screw fixing the pumping

member on the fork end to the prescri-
bed torque.

• Insert the spacer.

SUSP - 173
Suspensions GRISO 1100

Filling oil

• Place the sleeve upright in a vice fitted

with protection shoes.
• Compress the sleeve in the stem.
• Pour part of the fork oil into the sleeve.
• Wait some minutes until the oil fills all
the ducts.
• Pour the remaining oil.
• Pump out oil a few times.
• Measure the air gap between the oil
level and the rim.

THE SLEEVE MUST BE PERFECTLY UPRIGHT IN ORDER

TO MEASURE THE CORRECT OIL LEVEL. THE OIL LEVEL
MUST BE THE SAME IN BOTH STANCHIONS.

Characteristic
Fork oil
520 ± 2.5 cm³ (31.7 ± 0.15 in) (for each stem)
Oil level (from sleeve rim, without the spring
and washer)
114 mm (4.49 in).

• Place the washer.

• Fit the spring.

SUSP - 174
GRISO 1100 Suspensions

• Fit the complete preloading pipe.

• Fit the specified tool on the spring cou-

pling so that the cartridge stem is
locked in position.

Specific tooling
AP8140147 Spacer tool
8140148 Spacer / pumping member separating
plate

• Position the spacer and the washer.

SUSP - 175
Suspensions GRISO 1100

• Screw the upper cover on the cartridge

stem.

• Place the sleeve in the vice using the

specified tool.
• Screw the upper cover, tightening it to
the prescribed torque.

Specific tooling
AP8140149 Protection for fitting operations

Steering bearing

Adjusting play

• Undo and remove the two front screws.

SUSP - 176
GRISO 1100 Suspensions

• Undo and remove the two external

screws and move the instrument panel
forwards.

• Unscrew and remove the screws and

collect the U-bolts, holding the handle-
bar.
• Move the handlebar forward without
tilting the clutch and the front brake flu-
id reservoirs.

• Undo and remove the screw.

• Collect the right handlebar support.

• Unscrew and remove the fork upper

plate cover; collect the shim.

SUSP - 177
Suspensions GRISO 1100

• Working on both sides, unscrew and

remove the upper plate fixing screw on
the fork stems.

• Lift the fork upper plate sliding it off

from the stems.

• Rivet the safety washer on the head-

stock.

UPON REFITTING, REPLACE THE SAFETY WASHER WITH

A NEW ONE

• Using the suitable special tool, un-

screw and remove the upper ring nut.

Specific tooling
AP8140190 Tool for steering tightening

SUSP - 178
GRISO 1100 Suspensions

• Remove the safety washer.

• Using the suitable special tool, set the

preloading of the steering bearings.

Specific tooling
AP8140190 Tool for steering tightening

• Fit a new safety washer.

• Screw the upper ring nut manually and

then slightly tighten the clamps on the
plate so as to align notches on the ring
nut.

Specific tooling
AP8140190 Tool for steering tightening

SUSP - 179
Suspensions GRISO 1100

• Rivet the tongues of the new safety

washer.

• Fit the fork upper plate on the stems.

Rear

Removing the rear wheel

• Support the vehicle from the rear with

an adequate stand.
• Remove the cover.

• Engage the first gear.

• Undo and remove the four screws, col-
lect the spacers and the dust-protec-
tion ring.
• Remove rear wheel.

SUSP - 180
GRISO 1100 Suspensions

Shock absorbers

Removing

• Secure the vehicle handlebar from the

front with a hoist.

• Support the vehicle from below with a

suitable underpan jack.

• Support the vehicle from the front with

a suitable stand.

SUSP - 181
Suspensions GRISO 1100

• Unscrew and remove the fixing nut.

• Take out the screw tapping lightly with

a rubber hammer and follow as the as-
sembly slides out of its position.

• Undo and remove the suspension low-

er screw.

• Undo and remove the suspension up-

per screw.

SUSP - 182
INDEX OF TOPICS

CHASSIS CHAS
Chassis GRISO 1100

Swinging arm

Removing

• To remove the swingarm, first remove

both footrest supporting plates and the
exhaust silencer.
• Slide off the rear brake calliper from the
disc and release the brake pipe.
• Remove the cover.

• Engage the first gear.

• Unscrew and remove the four screws,
collecting the spacers and the dust pro-
tection ring.

• Remove the rear wheel.

• Unscrew and remove the nut fixing the

reaction rod.
• Remove the screw.
• Fix the reaction rod to the chassis with
a clamp.

CHAS - 184
GRISO 1100 Chassis

• Remove the clamp from the dust guard

cap.

• Loosen the two swingarm terminal

screws.

• Unscrew and remove the fixing nut of

the connecting rod assembly and col-
lect the screw.

• Disconnect the speed sensor connec-

tor and release the cable from the
clamps on the chassis.

CHAS - 185
Chassis GRISO 1100

• Loosen the ring nut.

Specific tooling
GU14912603 Hook spanner for fixing ring nut
of the clutch shaft internal body

• Helped by a second operator, remove

the pin and remove the swingarm to-
gether with the cardan shaft.

Checking

• Check that the universal joint is not

damaged, the gear teeth inserting in
the sleeve grooves and the grooves on
the joint are not deformed or damaged;
otherwise, replace the joint.
• Check that the rubber bellows are not
cut or pierced; otherwise, replace it.
• Check that the fork pin threads and the
fork fixing nuts are not damaged, de-
formed or flattened; otherwise, replace
them.
• Check that the sleeve grooves are not
damaged, deformed or deteriorated;
otherwise, replace the sleeve.
• Check that the sleeve outer toothing
and grooves are not damaged.

CHAS - 186
GRISO 1100 Chassis

Installing

• Spread a thin layer of lubricating

grease all along the swingarm pin.
• Fit the ring nut in the swingarm pin and
screw it manually.

• Working from both sides, grease the

cardan shaft cables with the recom-
mended product from the recommen-
ded products table.
• Block the swingarm, insert the univer-
sal joint, align the holes and, at the
same time, helped by a second opera-
tor, insert the pin completely.
• Tighten the swingarm pin.

• Use the suitable box-spanner to tight-

en the ring nut.

Specific tooling
GU14912603 Hook spanner for fixing ring nut
of the clutch shaft internal body

• Tighten the two screws of the swing-

arm clamp.

CHAS - 187
Chassis GRISO 1100

• Fit the dust guard cap in the gearbox.

• Lock the dust guard cap with a new
clamp.

• Place the reaction rod into its seat.

• Insert the screw.
• Screw the nut fixing the reaction rod.

• Place the connecting rod assembly on

the swingarm.
• Insert the screw.
• Tighten the fixing nut of the connecting
rod assembly.

• Connect the speed sensor connector

and fix the cable to the chassis with
clamps.

CHAS - 188
GRISO 1100 Chassis

• Place the rear wheel on the swingarm.

• Tighten the four screws with their
spacers and the dust-protection ring.
• Place the cover.
• Place the rear brake calliper on the disc
and the brake pipe on the swingarm.

See also

Recommended products chart

Bevel gears

Removing

• To remove the gearbox, first remove

the exhaust silencer and the rear
wheel.

• Unscrew and remove the nut fixing the

reaction rod.
• Remove the screw.
• Fasten the reaction rod to the chassis
with a clamp.

CHAS - 189
Chassis GRISO 1100

• Undo and remove the four screws.

• Remove the transmission casing slid-

ing off the universal joint.

Checking
Casing unit removal

CHAS - 190
GRISO 1100 Chassis

Casing unit removal

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 (16).

CHAS - 191
Chassis GRISO 1100

Collect the ring (15).

Remove the screws (7).

Remove the casing (4).

Remove the clamp (12).

Remove the cap (14).

CHAS - 192
GRISO 1100 Chassis

Collect the ring (13).

Remove the support unit (8).

Casing unit fitting

Casing unit fitting

Assemble the dowel pins to the casing with the
buffer and a hammer.

Assemble the casing to the special fastening tool.

Clean the casing faying surfaces carefully.

CHAS - 193
Chassis GRISO 1100

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.

CHAS - 194
GRISO 1100 Chassis

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.

Assemble two centring stud bolts with M8 thread

in the threaded holes of the casing as shown in the
picture.

CHAS - 195
Chassis GRISO 1100

Fit the casing.

Remove the two dowel pins.

Assemble the fixing screws (7).

Tighten the screws (7) to the prescribed torque.
Remove excessive sealant.

Assemble the ring to the casing.

Tighten the fixing screws to the prescribed torque.

CHAS - 196
GRISO 1100 Chassis

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 the transmission with the prescribed oil.

Fit the cap with the washer.
Screw the cap to the prescribed torque.

Assemble the cap with the clamps.

CHAS - 197
Chassis GRISO 1100

Fit the cap in its seat.

Wheel axle unit

Gruppo asse ruota

Removal
Remove the bearing from the wheel axle with a
suitable extractor.

Turn the unit over.

Remove the bearing from the wheel axle with a
suitable extractor.

FITTING
Heat the bearings to 100°C (212 °F).

CHAS - 198
GRISO 1100 Chassis

Assemble the bearings to the wheel axle.

Turn the unit over.

Assemble the bearings to the wheel axle.

Pinion unit

Pinion unit
Removal
Remove the stop ring (1) from the ring nut.

Unscrew the ring nut (2) with the special spanner

(s4).

CHAS - 199
Chassis GRISO 1100

Remove the ring nut (2) and remove the sealing

ring from the ring nut.
NOTE
THIS OPERATION DESTROYS THE SEALING RING.

Assemble the sealing ring (3) to the ring nut (2)

with the buffer CA715855 (see Fig.1) and a ham-
mer.

Lubricate the sealing ring (3).

Assemble the ring nut (2).

CHAS - 200
GRISO 1100 Chassis

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.

Assembly position of the stop ring (1).

CAUTION
MAKE SURE THE STOP RING IS IN ITS SEAT.

Support unit

CHAS - 201
Chassis GRISO 1100

Support unit
Removal
Remove the bushing (1) with a punch.
Turn the support (5) over and remove the other
bushing (8).

Remove the sealing rings (2) and (7) with a screw-

driver.
Remove the stop rings (3) and (6) from the support
(5) with suitable pliers.
NOTE
THIS OPERATION DESTROYS THE SEALING RING.

CHAS - 202
GRISO 1100 Chassis

Remove the ball joint (4) with a suitable buffer and

a rubber hammer.

FITTING
Fit the stop ring (6) in the support (5) with suitable
pliers.

Turn the support (5) over.

Assemble the ball joint (4) with the buffer and a
rubber hammer.

Fit the stop ring (3) in the support (5) with suitable
pliers.

CHAS - 203
Chassis GRISO 1100

Manually assemble the new sealing rings (2) and

(7).
Assemble the bushing (1).

Drive the bushing (1) in with a plastic hammer.

Turn the support (5) over and assemble the other
bushing (8).

TROUBLESHOOTING
Possible Cause Operation
1. Fitting error of the radial seal or seal damaged 2. Sliding 1. Replace the sealing ring and fit it correctly with the suitable
surface of the wheel axle seal spoiled or damaged tool
2. Replace the wheel axle
1. Casing not sealed 2. Closing screws of the casing shells not 1. Open the casing shells, clean the surfaces, seal and reas-
tightened to the prescribed torque semble the casing shells
2. Tighten the closing screws to the correct torque
1. Dirt between the sealing ring and the casing 2. A used seal- 1. Clean and tighten to the correct torque
ing ring has been fitted 3. Plug not tightened to the prescribed 2. Replace the sealing ring
torque 3. Tighten the plug to the correct torque
1. Cap damaged 2. Retaining clamp or closing cover loose 3. 1. Replace the cap
Fitting error of the radial seal or seal damaged 4. Sliding sur- 2. Screw the clamp with suitable pliers
face of the wheel spacer spoiled or damaged 3. Replace the sealing ring and fit it correctly with the suitable
tool
4. Replace the spacer
1. Cap damaged 2. Internal retaining clamp or external closing 1. Replace the cap
clamp loose 2. Screw the internal or external clamp with suitable pliers
1. Bevel gear pair fitting error 2. Bevel gear pair toothing spoiled 1. Replace the bevel gear pair
or damaged
1. Ball bearings on the wheel axle damaged 1. Replace the wheel bearings

CHAS - 204
GRISO 1100 Chassis

Installing

• Insert the transmission casing on the

swingarm making sure that the univer-
sal joint engages correctly.

• Tighten the four screws to the prescri-

bed torque operating diagonally.

• Place the reaction rod into its seat.

• Insert the screw.
• Screw the nut fixing the reaction rod.

• Place the dust-protection ring between

the rim and the cardan shaft taking
care to mount it with the collar facing
the transmission unit.

CHAS - 205
Chassis GRISO 1100

• Place the rear wheel on the swingarm.

• Tighten the four screws with their
spacers and the dust-protection ring.
• Place the cover.
• Place the rear brake calliper on the disc
and the brake pipe on the swingarm.

Exhaust

Removing the tail pipe

• Loosen the sealing clamp between the

exhaust and the central manifold.

• Unscrew and remove the two front at-

tachment screws fixing the exhaust to
the chassis; collect the lock nuts.

Locking torques (N*m)

Silencer to footrest support retainer 25 Nm

• Unscrew and remove the rear attach-

ment screw fixing the exhaust pipe to
the chassis; collect the lock nut, the
spacer and the washer.

DURING THIS OPERATION SUPPORT THE EXHAUST PIPE

SO THAT IT DOES NOT FALL.

Locking torques (N*m)

CHAS - 206
GRISO 1100 Chassis

Silencer to chassis connecting pipe retainer 25

Nm
• Remove the exhaust end.

Engine oil cooler

Key:
1. Complete oil radiator
2. Reduction
3. Aluminium gasket
4. Capstan screw
5. Right pipe
6. Left pipe
7. Deflector
8. M6x30 TE flanged screw
9. Washer
10. Bushing

CHAS - 207
Chassis GRISO 1100

11. Spacer
12. Rubber ring
13. Cap
14. Spacer
15. M8x30 TCC screw
16. Washer
17. M10x30 TCC screw
18. Washer
19. Radiator grille
20. M5x12 TBEI screw
21. T-shaped bushing

Removing

• Prepare a container and empty the lu-

brication system fluid in it.
• Unscrew and remove the screw and
collect the washer.

• Undo and remove the two screws; col-

lect the washers.

• Undo and remove the screw; collect

the washer.

CHAS - 208
GRISO 1100 Chassis

• Unscrew and remove the two screws;

collect the pipes and the four washers.

• Remove the oil cooling radiator.

CHAS - 209
INDEX OF TOPICS

BRAKING SYSTEM BRAK SYS

GRISO 1100 Braking system

Front brake pads

Removal

• Turn the pins and remove both split

pins.

• Remove both pins.

• Remove the vibration-damping plate.

• Extract one pad at a time.

CAUTION
AFTER REMOVING THE PADS, DO NOT OPERATE THE
BRAKE LEVER OR THE CALLIPER PLUNGERS COULD
GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID
LEAKS.

BRAK SYS - 211

Braking system GRISO 1100

Installing

• Insert two new pads, placing them so

that the holes are aligned with the cal-
liper holes.
CAUTION

ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY

ARE CORRECTLY POSITIONED INSIDE THE CALLIPER.

• Position the anti-vibration plate.

• Insert both pins.
• Position both split pins.
• Abut the plungers against the pads,
acting on the brake pump lever several
times.
• Check the brake fluid level in the res-
ervoir.

Rear brake pads

BRAK SYS - 212

GRISO 1100 Braking system

Removal

• Free the brake pipe and the throttle grip

cable from the clamps.

• Undo and remove the two screws.

• Remove the brake calliper from the
disc.
• Turn the pin and pull out the split pin.
• Remove the split pin.

• Remove the pin.

BRAK SYS - 213

Braking system GRISO 1100

• Extract one pad at a time.

CAUTION
AFTER REMOVING THE PADS, DO NOT OPERATE THE
BRAKE LEVER OR THE CALLIPER PLUNGERS COULD
GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID
LEAKS.

Installing

• Insert two new pads, placing them so

that the holes are aligned with the cal-
liper holes.
CAUTION

ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY

ARE CORRECTLY POSITIONED INSIDE THE CALLIPER.

• Insert the pin.

• Position the split pin.
• Insert the brake calliper into the disc by
screwing in the two screws.
• Abut the plungers against the pads,
acting on the brake pump pedal sever-
al times.
• Check the brake fluid level in the res-
ervoir.

BRAK SYS - 214

GRISO 1100 Braking system

Bleeding the braking system

Front

Any air trapped in the hydraulic circuit acts as a cushion, absorbing much of the pressure applied by
the brake pump and minimising the braking power of the calliper.
The presence of air is signalled by the "sponginess" of the brake control and poor braking efficiency.

CONSIDERING THE DANGER FOR VEHICLE AND RIDER, IT IS STRICTLY NECESSARY, AFTER
REFITTING BRAKES AND RESTORING THE BREAKING SYSTEM TO THE REGULAR USE CON-
DITIONS, THAT THE HYDRAULIC CIRCUIT BE AIR PURGED.
NOTE
THE FOLLOWING OPERATIONS REFER TO ONLY ONE FRONT BRAKE CALLIPER BUT APPLY
TO BOTH CALLIPERS. THE VEHICLE MUST BE ON LEVEL GROUND TO BE PURGED. WHILE
PURGING THE HYDRAULIC SYSTEM, FILL THE RESERVOIR WITH THE NECESSARY QUANTITY
OF BRAKE FLUID. CHECK THAT, DURING THE OPERATION, THERE IS ALWAYS BRAKE FLUID
IN THE RESERVOIR.
• Remove the rubber protection cover
from the bleed valve.
• Insert the transparent plastic pipe in
the front brake calliper bleed valve and
slide the other end of this pipe in a con-
tainer to collect the fluid.
• Remove the front brake oil reservoir
cap.
• Quickly press and release the front
brake lever several times and then
keep it fully pressed.
• Loosen the bleed valve 1/4 of a turn so
that the brake fluid flows into the con-
tainer. This will release the tension on

BRAK SYS - 215

Braking system GRISO 1100

the brake lever and will make it reach

the end of stroke.
• Close the bleed valve before the lever
reaches its end of stroke.
• Repeat the operation until the fluid
draining into the container is air-bubble
free.
NOTE
WHILE PURGING THE HYDRAULIC SYSTEM, FILL THE
RESERVOIR WITH THE NECESSARY QUANTITY OF
BRAKE FLUID. CHECK THAT, DURING THE OPERATION,
THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR.

• Screw the bleed valve and remove the pipe.

• Top-up the reservoir until the right brake fluid level is obtained.
• Refit and block the front brake oil reservoir cap.
• Refit the rubber protection cover.

Rear

Any air trapped in the hydraulic circuit acts as a cushion, absorbing much of the pressure applied by
the brake pump and minimising the braking power of the calliper.
The presence of air is signalled by the "sponginess" of the brake control and poor braking efficiency.
CAUTION
CONSIDERING THE DANGER FOR VEHICLE AND RIDER, IT IS STRICTLY NECESSARY, AFTER
REFITTING BRAKES AND RESTORING THE BRAKING SYSTEM TO THE REGULAR USE CON-
DITIONS, THAT THE HYDRAULIC CIRCUIT BE AIR PURGED. THE VEHICLE MUST BE ON LEVEL
GROUND TO BE PURGED. WHILE PURGING THE HYDRAULIC SYSTEM, FILL THE RESERVOIR
WITH THE NECESSARY QUANTITY OF BRAKE FLUID. CHECK THAT, DURING THE OPERATION,
THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR.
• Remove the rubber protection cover
from the bleed valve.
• Insert the transparent plastic pipe in
the rear brake calliper bleed valve and
insert the other end of this pipe into a
container to collect the fluid.
• Remove the rear brake oil reservoir
cap.
• Quickly press and release the rear
brake lever several times and then
keep it fully pressed.
• Loosen the bleed valve 1/4 of a turn so
that the brake fluid flows into the con-

BRAK SYS - 216

GRISO 1100 Braking system

tainer. This will release the tension on

the brake lever and will make it reach
the end of stroke.
• Close the bleed valve before the lever
reaches its end of stroke.
• Repeat the operation until the fluid
draining into the container is air-bubble
free.
NOTE
WHILE PURGING THE HYDRAULIC SYSTEM, FILL THE
RESERVOIR WITH THE NECESSARY QUANTITY OF
BRAKE FLUID CHECK THAT, DURING THE OPERATION,
THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR.

• Screw the bleeding valve and remove the pipe.

• Top-up the reservoir until the correct brake fluid level is obtained.
• Refit and lock the rear brake oil reservoir cap.
• Refit the rubber protection cover.

BRAK SYS - 217

INDEX OF TOPICS

BODYWORK BODYW
GRISO 1100 Bodywork

Rider footrest plate

RIGHT

• Undo and remove the two lower

screws and collect the nuts and the
spacers.
• Free the rear brake pipe from the
clamps and from pipe guide.
• Remove the rear brake calliper from
the disc.

• Unscrew and remove the rear upper

screw and collect the nut.

• Unscrew and remove the front upper

screw.

• Remove the air filter housing.

• Disconnect the connector of the rear
brake lever switch and release it from
the clamps.

BODYW - 219
Bodywork GRISO 1100

• Remove the right footrest plate, keep-

ing the brake fluid reservoir in vertical
position.

LEFT

• Remove the exhaust silencer.

• Undo and remove the screw and col-
lect the nut and the spacer.

• Unscrew and remove the rear upper

screw and collect the nut.

• Unscrew and remove the front upper

screw.

BODYW - 220
GRISO 1100 Bodywork

• Unscrew and remove the screw and

remove the left footrest plate.

See also
Air box

Air box

• Remove the fuel tank.

• Disconnect the connector from the air
temperature sensor.

• Slide off and remove the main fuse box

from its holder.

• Undo and remove the four screws.

BODYW - 221
Bodywork GRISO 1100

• Slide off and remove the secondary

fuse box from its holder.

• Undo and remove the two screws.

• Disconnect the low pressure pipe.

• Disconnect the blow-by tank breather
pipe.
• Free the pipes from the clamps.

BODYW - 222
GRISO 1100 Bodywork

• Release the breather pipe from the

clamp on the right side of the filter cas-
ing and the remove the pipe.
• Working on both sides, loosen the
clamp.
• Remove the filter casing by sliding it
backwards; collect the blow-by drain
pipe.

See also

Fuel tank

Fuel tank

• Remove both side fairings and the sad-

dle.
• Undo and remove the two front tank
fixing screws.

• Unscrew and remove the two screws

fixing the rear tank and recover the two
T spacers.
• Remove the battery.

• Lift the fuel tank at the front and then at

the rear by resting with the lower part,
the support rubber rings of the brackets
welded to the frame.
• Disconnect the quick connector.

BODYW - 223
Bodywork GRISO 1100

• Disconnect the connector.

• Remove the fuel tank.

BODYW - 224
INDEX OF TOPICS

PRE-DELIVERY PRE DE
Pre-delivery GRISO 1100

Carry out the listed checks before delivering the motorcycle.

WARNING

HANDLE FUEL WITH CARE.

Aesthetic inspection

- Paintwork
- Fitting of Plastic Parts
- Scratches
- Dirt

Tightening torques inspection

- Safety fasteners:
front and rear suspension unit
front and rear brake calliper retainer unit
front and rear wheel unit
engine - chassis retainers
steering assembly
- Plastic parts fixing screws

Electrical system

- Main switch
- Headlamps: high beam lights, low beam lights, tail lights (front and rear) and their warning lights
- Headlight adjustment according to regulations in force
- Front and rear stop light switches and their bulbs
- Turn indicators and their warning lights
- Instrument panel lights
- Instrument panel: fuel and temperature indicator (if present)
- Instrument panel warning lights
- Horn
- Electric starter
- Engine stop via emergency stop switch and side stand
- Helmet compartment electrical opening switch (if present)

PRE DE - 226
GRISO 1100 Pre-delivery

- Through the diagnosis tool, check that the last mapping version is present in the control unit/s and, if
required, program the control unit/s again: consult the technical service website to know about available
upgrades and details regarding the operation.
CAUTION

TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.

INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE
IT IS FIRST USED SHORTENS BATTERY LIFE.
CAUTION

UPON INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG-
ATIVE ONE, AND PERFORM THE REVERSE OPERATION UPON REMOVAL.
WARNING

THE BATTERY ELECTROLYTE IS POISONOUS AS IT MAY CAUSE SERIOUS BURNS. IT CON-

TAINS SULPHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING.
IN CASE OF CONTACT WITH YOUR EYES OR SKIN, WASH WITH ABUNDANT WATER FOR AP-
PROX. 15 MIN. AND SEEK MEDICAL ATTENTION IMMEDIATELY.
IF ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR
VEGETABLE OIL. SEEK MEDICAL ATTENTION IMMEDIATELY.
BATTERIES PRODUCE EXPLOSIVE GASES; KEEP CLEAR OF NAKED FLAMES, SPARKS OR
CIGARETTES. VENTILATE THE AREA WHEN RECHARGING INDOORS. ALWAYS WEAR EYE
PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES.
KEEP OUT OF THE REACH OF CHILDREN.
CAUTION

NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING
A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE
A FIRE.

Levels check
- Hydraulic braking system fluid level
- Clutch system fluid level (if present)
- Gearbox oil level (if present)
- Transmission oil level (if present)
- Engine coolant level (if present)
- Engine oil level
- Mixer oil level (if present)

Road test
- Cold start
- Instrument panel operation

PRE DE - 227
Pre-delivery GRISO 1100

- Response to throttle control

- Stability when accelerating and braking
- Front and rear brake efficiency
- Front and rear suspension efficiency
- Abnormal noise

Static test

Static check after test drive:

- Restarting when warmed up
- Starter operation (if present)
- Minimum holding (turning the handlebar)
- Uniform turning of the steering
- Possible leaks
- Radiator electric fan operation (if present)

Functional inspection

- Hydraulic braking system

- Stroke of brake and clutch levers (if present)
- Clutch - Check for correct operation
- Engine - Check for correct general operation and absence of abnormal noise
- Other
- Documentation check:
- Chassis and engine numbers check
- Supplied tools check
- License plate fitting
- Locks checking
- Tyre pressure check
- Installation of mirrors and any possible accessories

NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES AS TYRES MAY BURST.

CAUTION

CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.

PRE DE - 228
A
Air filter: 34
Air temperature sensor: 56, 58

B
Battery: 49, 54
Brake: 211, 212
Brake pads: 211, 212

C
Chain: 117, 120, 121
Clutch: 89, 92–94, 102, 104, 105
Coil: 57
Connectors: 58
Crankcase: 19, 134
Crankshaft: 19, 134, 136, 138
Cylinder: 18, 108, 110, 113, 128, 129, 131, 132, 136

D
Desmodromic drum: 91
Display: 156

E
Electrical system: 12, 42, 43, 226
Engine oil: 31, 207
Engine temperature sensor: 55
Exhaust: 206

F
Fairings:
Fork: 160, 163, 166, 170
Forks: 91
Front wheel: 159, 163
Fuel: 223
Fuel pump:
Fuses: 51

G
Gearbox oil: 33

H
Handlebar:
Head cover: 107, 111, 134

I
Identification: 10
Instrument panel: 58
M
Maintenance: 8, 29

O
Oil filter: 33
Oil pressure sensor: 57
Oil sump: 140, 143

P
Primary shaft: 84, 90, 92

R
Rear wheel: 180
Recommended products: 20, 189

S
Secondary shaft: 86, 91, 92
Shock absorbers: 181
Side stand:
Speed sensor: 54
Stand:
Start-up: 50
Starter motor: 79, 101

T
Tank: 223
Transmission: 12, 30
Tyres: 14

W
Wiring diagram: 44