SERVICE STATION MANUAL

854366

BELLAGIO

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 SERVICE STATION
MANUAL

BELLAGIO

THE VALUE OF SERVICE

Only the mechanics of the Official Moto Guzzi Service Network know this vehicle well, thanks to constant
technical professional development and Moto Guzzi specific training programmes, and have the tools
needed to carry out maintenance and repair operations correctly.
The reliability of the vehicle also depends on its mechanical conditions. Checking the vehicle before
setting off, carrying out routine maintenance and using only Moto Guzzi Original Spare parts is
fundamental!
For information about the nearest Official Dealer and/or Service Centre, consult the Yellow Pages or
search directly on the inset map in our Official Website:
www.motoguzzi.it
Only by purchasing Moto Guzzi Original Spare Parts will you get a product designed and tested during
the bike designing phase. Moto Guzzi Original Spare Parts are subject to systematic quality control
procedures so that their reliability and performance over time is guaranteed.
The descriptions and illustrations given in this publication are not binding; While the basic features as
described and illustrated in this booklet remain unchanged, Moto Guzzi reserves the right, at any time
and without being required to update this publication beforehand, to make any changes to components,
parts or accessory supplies, which it deems necessary to improve the product or which are required for
manufacturing or commercial reasons.
Not all versions shown in this publication are available in all Countries. The availability of individual
versions should be checked with the Official Moto Guzzi sales network.
© Copyright 2007- Moto Guzzi. All rights reserved. Reproduction of this publication in whole or in part is
prohibited. Moto Guzzi - After sales service.

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 SERVICE STATION MANUAL
BELLAGIO
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

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 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

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 INDEX OF TOPICS

CHARACTERISTICS CHAR

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 BELLAGIO 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

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 Characteristics BELLAGIO

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

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 BELLAGIO 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

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 Characteristics BELLAGIO

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

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This number is composed by numbers and letters,

as in the example shown below.
ZGULY0000YMXXXXXX
KEY:
ZGU: WMI (World manufacturer identifier) code;
LY: 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 2253 mm (88.70 in)
Length (Luxury) 2276 mm (89.60 in)
Width (to the brake / clutch levers) 820 mm (32.30 in)
Height (to the brake pumps / clutch) 1130 mm (44.50 in)
Height (to the brake pumps / clutch) (Luxury) 1110 mm (43.70 in)
Saddle height 780 mm (30.71 in)
Saddle height (Luxury) 760 mm (29.92 in)
Minimum ground clearance 150 mm (5.9 in)
Minimum ground clearance (Luxury) 105 mm (4.13 in)
Wheelbase 1560 mm (61.42 in)
Wheelbase (Luxury) 1565 mm (61.61 in)
Kerb weight 237 kg (522 lb)

CHAR - 11

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 Characteristics BELLAGIO

Engine

ENGINE
Specification Desc./Quantity
Type traverse-mounted twin-cylinder four-stroke V 90°
No. of cylinders 2
Cylinder arrangement V 90°
Cubic capacity 935.6 cm³ (57.09 cu.in)
Bore / stroke 95 x 66 mm (3.74 x 2.66 cu.in)
Compression ratio 10:1
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
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
Gear ratio Primary gears 24/35
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 sump 3000 cm³ (183 cu.in)
Gearbox oil 500 cm³ (30.5 cu.in)
Transmission oil 380 cm³ (23.2 cu.in)
Fuel (reserve included) 19 +/- 0.5 l (5.02 +/- 0.13 US gal)
Fuel reserve 4 l (1.056 US gal)
Adjustable telescopic fork oil (per fork leg) 0.485 l (0.128 US gal)
Seats 2
Vehicle maximum load 210 kg (463 lb) (rider + passenger + luggage)

Electrical system

ELECTRICAL SYSTEM
Specification Desc./Quantity
Spark plugs - inner long life, 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

CHAR - 12

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Specification Desc./Quantity
Generator - alternator Output power: 350 W at 5000 rpm (12V - 25A)
Main fuses 30 A
Auxiliary fuses 3 A - 15 A
Daylight running light 12V - 5 W
Low/High beam headlight (halogen) 12 V - 55 W / 60 W H4
Turn indicators 12V - 10 W
Rear tail light /stop light 12 V - 5 / 21 W
Dashboard lighting LED
License plate light 12V - 5 W
Turn indicator warning light LED
Neutral gear warning light LED
Side stand down warning light LED
Low fuel warning light LED
High beam warning light LED
Oil pressure warning light LED
General alarm warning light LED

Frame and suspensions

CHASSIS - SUSPENSIONS
Specification Desc./Quantity
Chassis Double cradle, high strength steel tube chassis
Headstock angle 28°
Trail 92 mm (3.62 in)
Front suspension MARZOCCHI hydraulic telescopic fork, ∅ 45 mm (1.77 in) with
separate adjustment for rebound and compression damping.
Front wheel travel 140 mm (5.5 in)
Rear suspension - type single arm suspension with progressive rising-rate leverage,
single shock absorber with adjustable rebound and with ergo-
nomic knob for preloading adjustment.
Rear wheel travel 120 mm (4.7 in)
Rear wheel travel (Luxury) 61 mm (2.4 in)

SIZES A AND B
Specification Desc./Quantity
Size A 764.74 mm (30.1 in)
Size B 404.25 mm (15.91 in)

Brakes

BRAKES
Specification Desc./Quantity
Front stainless steel Ø 320 mm (12.6 in) twin floating disc, Brembo
floating callipers with 2 parallel plungers
Rear stainless steel Ø 282 mm (11.1 in) fixed disc, Brembo floating
calliper with 2 parallel pistons

CHAR - 13

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Wheels and tyres

WHEELS AND TYRES

Specification Desc./Quantity
Wheel rims with spokes
Front wheel rim 3.5" x 18''
Rear wheel rim 5.50 x 17
Tyres - Front size 120/70 - ZR 18'' M/C 59 W
Tyres - Rear size 180/55 - ZR 17'' M/C 73 W
Tyres METZELER Roadtec Z6
Pirelli Angel ST
Dunlop Sportmax Roadsmart
Inflation pressure (front) 2.3 bar (230 kPa) (33.4 PSI)
Inflation pressure with passenger (front) 2.3 bar (230 kPa) (33.4 PSI)
Inflation pressure (rear) 2.5 bar (250 kPa) (36.3 PSI)
Inflation pressure with passenger (rear) 2.7 bar (270 kPa) (39.1 PSI)

Supply

SUPPLY
Specification Desc./Quantity
Supply MAGNETI MARELLI IAW MULTIPOINT electronic phased se-
quential fuel injection, ALFA-N System.
Diffuser diameter: 40 mm (1.57 in)
Fuel Premium unleaded petrol, minimum octane rating 95 (NORM)
and 85 (NOMM)

Tightening Torques

HEADS
Name Torque in Nm
Oil cap (2) 25 Nm (18.44 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

CHAR - 14

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OIL SUMP
Name Torque in Nm
Oil sump centre lower screws - TE M6x90 (4) 10 Nm (7.38 lbf ft)
Oil sump screw - TCEI M6x25 (14) 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
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)
Alternator locking nut - M16x1.5 (1) 80 Nm (59 lbf ft) - Loctite 243
Camshaft support screw on timing system cover - TCEI M4x10 5 Nm (3.69 lbf ft) - Loctite 243
(4)

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
Name Torque in Nm
Electronic control unit lower retainer - M6x20 (2) 10 Nm (7.38 lbf ft)
Electronic control unit upper retainer - M6x35 (2) 10 Nm (7.38 lbf ft) - Loctite 243
Tank to chassis support rubber rings retainer - M8x18 (2) 25 Nm (18.44 lbf ft)
Gearbox to chassis retainer - M12 (1+1) 50 Nm (36.88 lbf ft)
Engine support front plate retainer - M12x50 (2) 80 Nm (59 lbf ft)
Rider left and right footrest to chassis support retainer - M8x65 25 Nm (18.44 lbf ft)
(4)
Passenger left and right footrest to chassis support retainer - 25 Nm (18.44 lbf ft)
M8x25 (4)
Filter box holding rear bracket to chassis retainer - M8x16 (2) 15 Nm (11.06 lbf ft)
Rider heel rest to footrest support plate retainer - M5x15 (6) 6 Nm (4.42 lbf ft)
Stud bolt for fixing front bulkheads on the steering sleeve - 10 Nm (7.38 lbf ft)
M6x1 (2)

CHAR - 15

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FOOTRESTS AND LEVERS

Name Torque in Nm
Footrest rubber retainer - M6x12 (8) 10 Nm (7.38 lbf ft)
Gear shift lever cable retainer (nut) - M6x1 (2) 10 Nm (7.38 lbf ft)
Gear shift lever / brake pin retainer - M6x16 (1+1) 10 Nm (7.38 lbf ft)
Gear shift lever pin retainer - M8 (1) 15 Nm (11.06 lbf ft) - Loctite 243
Preselector lever retainer - M6x20 (1) 10 Nm (7.38 lbf ft)

SIDE STAND
Name Torque in Nm
Stand plate to engine retainer - M12x35 (2) 80 Nm (59 lbf ft)
Side stand retainer bolt - M10x1.25 (1) 10 Nm (7.38 lbf ft)
Switch retainer - M5x16 (2) 6 Nm (4.42 lbf ft)
Pin lock nut - M10x1.25 (1) 30 Nm (22.13 lbf ft)

SWING ARM
Name Torque in Nm
Swingarm clamp on bushing retainer - M6x25 (2) 10 Nm (7.38 lbf ft)
Fork on cardan shaft housing retainer - M10x35 (4) 50 Nm (36.88 lbf ft)
Torque arm to cardan shaft housing retainer - M10x55 (1) 50 Nm (36.88 lbf ft)
Brake torque arm to chassis retainer - M10x55 (1) 50 Nm (36.88 lbf ft)
Fork pin to fork retainer - M20x1.5 (1) 60 Nm (44.25 lbf ft)
Preloading bushing to fork pin retainer - M25x1.5 (1) 10 Nm (7.38 lbf ft)

FRONT SUSPENSION
Name Torque in Nm
Fork stem on lower/upper plate retainer - M8x30 (6) 25 Nm (18.44 lbf ft)
Headstock nut - M23x1 (1) 50 Nm (36.88 lbf ft)
Headstock ring nut - M25x1 (1) 7 Nm (5.16 lbf ft) - the headstock should turn freely
Fork stem cap (2) 25 Nm (18.44 lbf ft)
Fork hub closing - M6x40 (2+2) 10 Nm (7.38 lbf ft)

REAR SUSPENSION
Name Torque in Nm
Shock absorber to chassis retainer - 8.8 M10x80 (1) 50 Nm (36.88 lbf ft)
Double connecting rod / shock absorber retainer 10.9 M10x47 40 Nm (29.5 lbf ft)
(1)
Single connecting rod / double connecting rod retainer 10.9 50 Nm (36.88 lbf ft)
M10x95 (1)
Single connecting rod to chassis retainer - 8.8 M10x85 (1) 50 Nm (36.88 lbf ft)
Double connecting rod / fork retainer 10.9 M10x82 (1) 50 Nm (36.88 lbf ft)

FILTER CASING
Name Torque in Nm
Filter casing cover retainer - M5x30 (3) 6 Nm (4.42 lbf ft)
Filter casing to chassis bracket retainer - M6x12 (1) 10 Nm (7.38 lbf ft)

EXHAUST
Name Torque in Nm
Exhaust pipe to engine retainer - M8x1.25 (4) 25 Nm (18.44 lbf ft)
Exhaust pipe to compensator retainer (clamp) - M6 (2) 10 Nm (7.38 lbf ft)
Compensator to plate retainer - M10 (2) 25 Nm (18.44 lbf ft)
Compensator to muffler retainer (clamp) - M6 (2) 10 Nm (7.38 lbf ft)
Lambda probe retainer - M18x1.5 (1) 38 Nm (28.03 lbf ft)
Mufflers to support retainer - M8x25 (4) 25 Nm (18.44 lbf ft) - Loctite 601
Muffler support to chassis retainer - M8 (1) 25 Nm (18.44 lbf ft)

FRONT WHEEL
Name Torque in Nm
Brake disc retainer - M8x20 (12) 30 Nm (22.13 lbf ft) - Loctite 243

CHAR - 16

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 BELLAGIO Characteristics

Name Torque in Nm
Wheel pin - M18x1.5 (1) 80 Nm (59 lbf ft)

REAR WHEEL
Name Torque in Nm
Brake disc retainer - M8x20 (6) 30 Nm (22.13 lbf ft) - Loctite 243
Rear wheel retainer - 10.9 M12x65 (4) 110 Nm (81.13 lbf ft)

FRONT BRAKING SYSTEM

Name Torque in Nm
Front brake right and left calliper retainer - M10x30 (2+2) 50 Nm (36.88 lbf ft)

REAR BRAKING SYSTEM

Name Torque in Nm
Rear calliper retainer - M10x30 (2) 50 Nm (36.88 lbf ft)
Rear brake lever pin - M8 (1) 15 Nm (11.06 lbf ft) - Loctite 243
Rear brake fluid reservoir retainer - SWP 5x20 (1) 3 Nm (2.21 lbf ft)
Rear brake fluid reservoir on plate support retainer - M6x16 (1) 10 Nm (7.38 lbf ft)
Rear brake rod lock nut - M6 (1) manual
Brake pump retainer - M6x20 (2) 10 Nm (7.38 lbf ft) - Loctite 243

HANDLEBAR AND CONTROLS

Name Torque in Nm
Handlebar on steering plate retainer - M10x60 (2) 50 Nm (36.88 lbf ft)
Clutch and brake pump u-bolt retainer - M6 (2+2) 10 Nm (7.38 lbf ft)
Right and left light switch retainer - M5 (2) 1.5 Nm (1.11 lbf ft)
Clutch pump to transmission retainer - M6 (3) 10 Nm (7.38 lbf ft)
Mirror - M10 (1+1) Manual

ELECTRICAL SYSTEM
Name Torque in Nm
Horn retainer screw + nut - M8x20 (1) 15 Nm (11.06 lbf ft)
Coil retainer - AT M4x25 (4) 3 Nm (2.21 lbf ft)
Odometer sensor on cardan shaft housing retainer - M4x10 (2) 3 Nm (2.21 lbf ft)

INSTRUMENT PANEL AND LIGHTS

Name Torque in Nm
Instrument panel support to light support retainer - M6x20 (4) 10 Nm (7.38 lbf ft)
Front light supports to fork plate retainer - M6x18 (4) 10 Nm (7.38 lbf ft)
Headlamp retainer - M8x30 (2) 15 Nm (11.06 lbf ft)
Front and rear turn indicator retainer (screw + nut) - M6 (2+2) 5 Nm (3.69 lbf ft)
Rear light to tail retainer - M5x18 (3) 4 Nm (2.95 lbf ft)

FUEL PUMP FLANGE

Name Torque in Nm
Pump support to tank retainer - M5x16 (6) 6 Nm (4.42 lbf ft)

FUEL TANK
Name Torque in Nm
Filler to tank retainer - M4x16 (5) 3 Nm (2.21 lbf ft)
Tank rear retainer - M8x45 (1) 25 Nm (18.44 lbf ft)

CHASSIS/ FAIRINGS (FRONT)

Name Torque in Nm
Stabilisation plate to fork retainer - M8x35 (4) 15 Nm (11.06 lbf ft) - Loctite 243
Front mudguard to stabilisation plate retainer - M6x22 (4) 10 Nm (7.38 lbf ft) - Loctite 243
Engine closing plate to chassis front retainer - M5x12 (2) 4 Nm (2.95 lbf ft)
Engine closing plate to chassis rear retainer - M5x20 (2) 4 Nm (2.95 lbf ft)

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 Characteristics BELLAGIO

CHASSIS / FAIRINGS (CENTRE)

Name Torque in Nm
Right and left throttle body cover upper retainer - M5x20 (2) 4 Nm (2.95 lbf ft) - Loctite 243
Right and left throttle body cover lower retainer - M5x20 (2) manual
Right and left side fairing retainer - M5x9 (4) 4 Nm (2.95 lbf ft)

CHASSIS/ FAIRINGS (REAR)

Name Torque in Nm
Tail section / battery holder mudflap / license plate holder re- 4 Nm (2.95 lbf ft)
tainer - M5x9 (12)
Retroreflector to support retainer - M5 (1) 4 Nm (2.95 lbf ft)
Retroreflector support on license plate holder retainer - M5x12 4 Nm (2.95 lbf ft)
(1)
License plate lamp, license plate holder, retroreflector support 4 Nm (2.95 lbf ft)
retainer - M5x22 (1)

FINISHING
Name Torque in Nm
Ignition lock retainer - shear head screw - M8x15 (1) at the point of failure
Ignition lock retainer - M8x16 (1) 25 Nm (18.44 lbf ft)

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 95.000 - 95.020 mm (3.7401 - 3.7409 in)
piston diameter 94.942 - 94.972 mm (3.7379 - 3.7390 in)
fitting clearance 0.048 - 0.068 mm (0.00189 - 0.00268 in)

CHAR - 18

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 BELLAGIO Characteristics

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
(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)

CHAR - 19

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 Characteristics BELLAGIO

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
ENI i-RIDE PG 10W-60 Lubricant formulated with advanced syn- JASO MA, MA2 - API SG
thetic technology and high performance
additives to cater specifically for 4-stroke
engines with high specific power outputs.
AGIP GEAR SAE 80 W 90 Transmission oil API GL-4
AGIP GEAR MG/S SAE 85 W-90 Gearbox oil API GL-5
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 fluid SAE J 1703 -FMVSS 116 - DOT 3/4 - ISO
4925 - CUNA NC 956 DOT 4 synthetic
fluid
AGIP BRAKE 5.1 Clutch fluid FMVSS 116 - DOT 5.1 Non-silicone syn-
thetic fluid
NOTE
USE ONLY NEW BRAKE FLUID. DO NOT MIX DIFFERENT BRANDS OR TYPES OF OIL WITHOUT
CHECKING THEIR BASE COMPATIBILITY.

CHAR - 20

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 INDEX OF TOPICS

SPECIAL TOOLS S-TOOLS

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 Special tools BELLAGIO

SPECIAL TOOLS
Stores code Description
05.90.25.30 Gearbox support

14.92.72.00 Tool for fitting the sealing ring on the tim-

ing system cover

05.91.25.30 Gearbox opening

05.90.19.30 Inner spark plug removal

05.92.80.30 Piston ring clamp

14.92.91.00 Punch for pressing the sealing ring on the

front fork sleeve and sealing ring inside
the gearbox.

S-TOOLS - 22

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 BELLAGIO Special tools

Stores code Description

19.92.96.00 Graduated dial 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

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

S-TOOLS - 23

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 Special tools BELLAGIO

Stores code Description

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

14.92.73.00 Tool for camshaft gear sealing

981001 Graduated dial hub

30.91.28.10 Clutch body locking

000019663300 Tool for clutch shaft removal

05.90.27.30 Gearbox support

05.90.27.31 Gearbox oil seal buffer

S-TOOLS - 24

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 BELLAGIO Special tools

Stores code Description

05.90.27.32 Buffer handgrip

05.90.27.33 Ball joint sealing buffer

05.90.27.34 Wrench for pinion ring nut

05.90.27.35 Pinion oil seal buffer

GU14912603 Hook spanner for fixing ring nut of the

clutch shaft internal body

S-TOOLS - 25

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 INDEX OF TOPICS

MAINTENANCE MAIN

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 BELLAGIO 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

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 Maintenance BELLAGIO

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 - 28

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 BELLAGIO 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.

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 Maintenance BELLAGIO

• 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 - 30

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 BELLAGIO Maintenance

• Screw and tighten the drainage plug

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

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:

• 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.

MAIN - 31

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 Maintenance BELLAGIO

• 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

• Remove the fuel tank.

• Undo and remove the three screws
from the filter casing cover.

MAIN - 32

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 BELLAGIO Maintenance

• Remove the filter casing cover from the

clamps.
• Remove the air filter.
NOTE
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.

See also

Fuel tank

Checking the valve clearance

If the timing system is very noisy, check the clearance between valves and rocking levers.
NOTE
ADJUST WITH COLD ENGINE, WITH PISTON AT TOP DEAD CENTRE (TDC) IN COMPRESSION
STROKE (VALVES CLOSED).
• Remove the fuel tank.
• Unscrew and remove the two screws.
• Remove the spark plugs protection.
• Disconnect both spark plug tubes.

• Unscrew and remove the eight screws.

• Remove the head cover.

MAIN - 33

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 Maintenance BELLAGIO

• 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 TAPPET WILL BE NOISY. OTHER-
WISE, THE VALVES DO NOT CLOSE CORRECTLY, WHICH CAN LEAD TO PROBLEMS SUCH
AS:
• PRESSURE DROP;
• ENGINE OVERHEAT;
• VALVE BURNOUT, 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 - 34

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 BELLAGIO 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 - 35

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 Maintenance BELLAGIO

MAIN - 36

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 INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

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 Electrical system BELLAGIO

Components arrangement

Key:

1. Coil
2. Instrument panel
3. Fuel pump

ELE SYS - 38

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 BELLAGIO Electrical system

4. Injector
5. Throttle valve potentiometer
6. Rear light
7. Battery
8. Main fuses
9. Lambda Probe
10.Starter motor
11.Intake air temperature sensor
12.Engine revolution sensor
13.Secondary fuses
14.Head temperature sensor
15.Engine control unit
16.Instrument panel air temperature sensor
17.Front headlamp
18.Oil pressure sensor
19.Speed sensor
20.Alternator
21.License plate light

Electrical system installation

ELE SYS - 39

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 Electrical system BELLAGIO

General wiring diagram

Key:

1. Multiple connectors
2. -
3. Start-up relay
4. Clutch switch

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 BELLAGIO Electrical system

5. Light relay
6. Right light switch
7. Safety diode
8. Horn
9. Left light switch
10.Instrument panel air temperature thermistor
11.Instrument panel
12.Instrument panel diagnosis
13.Key switch
14.Front stop switch
15.Right rear turn indicator
16.Rear light (LED)
17.Left rear turn indicator
18.License plate light
19.Rear stop switch
20.(ECU) Diagnosis connector
21.Secondary fuses
22.Main fuses
23.Starter motor
24.Battery
25.Voltage regulator
26.350 W alternator
27.Main injection relay
28.Injection diode
29.Secondary injection relay
30.Oil pressure sensor
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 sensor
38.-
39.Throttle sensor
40.Right cylinder inner spark plug
41.Right cylinder outer spark plug
42.Left cylinder inner spark plug

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43.Left cylinder outer spark plug

44.Right cylinder double coil
45.Left cylinder double coil
46.Right injector
47.Left injector
48.Speed sensor
49.Fall sensor
50.Flywheel pick up
51.Pick-up wire shielding
52.ECU
53.Left front turn indicator
54.Tail light bulb
55.High - low-beam bulb
56.Front headlamp
57.Right front turn indicator
58.GPS coupling
59.Antitheft coupling

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

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 BELLAGIO Electrical system

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
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
For this vehicle the SERVICE CODE is: 21959
The functions in this menu are
• Exit
• ECU errors
• Instrument Panel Errors
• Delete errors
• Reset Service
• Update
• Change Keys
ECU ERRORS
The instrument panel receives only the current errors from the control unit.
Description - Error code
Throttle Valve Error DC Vdc - ECU 10
Throttle Valve Error DC Gnd - ECU 11
Engine Temperature Error DC Vdc - ECU 14
Engine Temperature Error DC Gnd - ECU 15
Air Temperature Error DC Vdc - ECU 16
Air Temperature Error DC Gnd - ECU 17
Low Battery Error - ECU 20
Lambda Probe Error - ECU 21
Coil 1 Error DC Vdc - ECU 22
Coil 1 Error DC Gnd - ECU 23
Coil 2 Error DC Vdc - ECU 24
Coil 2 Error DC Gnd - ECU 25

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Injector 1 Error DC Vdc - ECU 26

Injector 1 Error DC Gnd - ECU 27
Injector 2 Error DC Vdc - ECU 30
Pump Relay Error - ECU 36
Local Loop-back Error - ECU 37
DC Start-up Remote control Error Vdc - ECU 44
Remo. Error DC Start-up Gnd - ECU 45
Canister Error DC Vdc - 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
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 - Error code
Fuel sensor failure - DSB 05 Air temperature sensor failure - DSB 06 Oil sensor failure - DSB 07 Oil
pressure failure - 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.

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.

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Battery recharge circuit

Checking the stator

INVERTED CONNECTION WILL CAUSE IRREPARABLE

DAMAGE TO THE REGULATOR.
MAKE SURE THAT THE REGULATOR HAS A CORRECT
GROUND CONNECTION.
POSSIBLE CHECKS TO BE CARRIED OUT ON THE AL-
TERNATOR AND ON THE REGULATOR IN CASE THAT
THE BATTERY IS RECHARGED OR THAT VOLTAGE IS NO
LONGER REGULATED.

With engine off disconnect the two generator yellow cables from the rest of the system and, with an
Ohm meter, carry out the following checks:
WINDING TOWARD THE GROUND INSULATION CHECK
Connect an Ohm meter lead to one of the two yellow cables and the other lead to the ground connection
(reed valve). The Ohm meter should indicate a value above 10 MOhm.
WINDING CONTINUITY CHECK
Connect the Ohm meter to the ends of the two yellow cables.
The Ohm meter should indicate a value between 0.2 and 0.3 Ohm.
OUTPUT VOLTAGE CHECK
Connect a voltmeter set to 200 V alternating current capacity to the ends of the two yellow cables.
Start up the engine and check that the output voltages are within the values indicated in the table.

ALTERNATOR CHECK
Specification Desc./Quantity
1 Alternating current voltage at 1000 rpm 15V or above
2 Alternating current voltage at 3000 rpm 40V or above
3 Alternating current voltage at 6000 rpm 80V or above
4 Direct current intensity at 1000 rpm 9.50 Amp
5 Direct current intensity at 1200 rpm 13.0 Amp
6 Direct current intensity at 1500 rpm 16.50 Amp
7 Direct current intensity at 2000 rpm 20.0 Amp
8 Direct current intensity at 3000 rpm 23.50 Amp
9 Direct current intensity at 4000 rpm 25.0 Amp
10 Direct current intensity at 6000 rpm 26.50 Amp
11 Direct current intensity at 10000 rpm 27.50 Amp

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Voltage regulator check

The regulator is calibrated to keep battery voltage

between 14 and 14.6 V.
Regulator checks
Regular tools in the shop are not enough to carry
out the regulator check, therefore, there follow
some indications for effectively detecting a faulty
regulator.
A regulator is faulty if:
After being disconnected from the rest of the sys-
tem, it has a short circuit between the ground
connection (aluminium sheath) and any output ca-
ble.

See also
Checking the stator

Start-up system check

GENERAL CHARACTERISTICS
Specification Desc./Quantity
1 Voltage 12 V
2 Power 1.2 kW
3 Torque at idle speed 11 Nm
4 Torque when loading 4.5 Nm
5 Pinion z = 9 module 2.5
6 Rotation (pinion side) Anticlockwise
7 Speed 1750 rpm
8 Current at idle speed 600 A
9 Current when loading 230 A
10 Weight 2.8 kg (61.73 lb)

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Lights list

ELECTRICAL SYSTEM
Specification Desc./Quantity
Daylight running light 12V - 5 W
Low/High beam headlight (halogen) 12 V - 55 W / 60 W H4
Rear tail light /stop light 12 V - 5 / 21 W
License plate light 12V - 5 W

Fuses

SECONDARY FUSES
A - Stop, horn, coil, light relay (15 A).
B - Tail lights, license plate light, passing, ignition
relay (15 A).
C - Positive live lead, "Tom - Tom" GPS (3A)
D - Fuel pump, coils, injectors (15 A).
D - Lambda burner, secondary injection relay coil,
ignition relay coil, speed sensor power supply, en-
gine kill, ECU power supply (15 A).
F- Permanent positive, ECU power supply (3A).
NOTE
THERE ARE TWO SPARE FUSES.

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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.

Control unit

Model: Magneti Marelli IAW 5 AM

The control unit structure has ground connection

MARELLI CONTROL UNIT

Function
It manages injection/ignition, the system safety checks and the self-diagnosis function.
Location:
• central, under the tank.

Pin-out: see the CONNECTORS section

THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION
TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM
THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE
"MAIN" CABLE HARNESS AND INTO THE CONNECTOR/COMPONENT.
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROU-
BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK
AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
AXONE: FUEL INJECTION SYSTEM
PARAMETERS
Target engine revs

STATUSES
Engine status
Example value:ON/run/power-latch/stopped.

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Ignition
Example value: Enabled/Disabled
Indicates whether the control unit will enable start-up when requested: in case these safety measures
are not respected (correct position of side stand, neutral sensor and clutch), the status is NO.

AXONE: ACTIVATIONS
Error clearing

AXONE: ELECTRICAL ERRORS

RAM Memory - ROM Memory - Microprocessor - Checksum EEPROM.
Error cause

• Possible internal control unit error. Also check the control unit supply and ground connec-
tions.

Troubleshooting

• If the power supply and ground connections are connected correctly, replace the injection
control unit.

NEW CONTROL UNIT ACTIVATION PROCEDURE

• After installing a new control unit, it is necessary to carry out the Throttle positioner auto-
detection function using the diagnosis instrument

Battery

12 V - 18 Ampere/hour

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Speed sensor

Function
To indicate the vehicle speed by reading the rear
wheel turning speed.
Operation / Operating principle
HALL effect sensor: a square-wave pulse is gen-
erated with voltage between 12 V and 0.3-0.4V
approx.
Level in wiring diagram:
Speed sensor
Location:

• sensor: on swingarm, right side, near

the rear brake calliper
• connector: under the saddle, next to
the right fairing

Pin-out:

• PINS 1-3 Voltage: approx. 12 V

• PINS 2-3 Voltage: variable 0.4V-12V
(by turning the rear wheel)

PIN:

1. Supply voltage (green)

2. Output signal (grey/white)
3. Ground (blue/orange)

AXONE: ELECTRICAL ERRORS

Speed sensor - invalid signal.
Error cause

• Error signal if a speed below the default value set by the manufacturer for the running vehicle
is detected. Possibly shorted to ground, to battery or speed sensor circuit open: lack of
supply from the control unit also possible.

Troubleshooting
CARRY OUT THE CASCADE OPERATIONS UNTIL THE FAILURE IS FOUND

• Check correct position of the sensor in its fitting.

• Check voltage between PINS 1-3 of the sensor. In case of null voltage, check continuity
between PIN 1 of the sensor and PIN 17 of the ECU BLUE connector.
• Check PIN 17 of the blue connector.
• Check continuity to ground of PIN 3 of the sensor.

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• Check continuity of the cable between PIN 2 of the sensor and PIN 24 of the ECU blue
connector.
• Check PIN 24 of the blue connector.
• If after all these checks the failure is not found, replace the sensor.
Speed sensor - over the maximum limit.
Error cause
• Error signal if a speed above the default value set by the manufacturer for the running vehicle
is detected.
Troubleshooting
• if over the maximum limit: replace the sensor.

Engine rpm sensor

Function
It informs crankshaft position and speed to the
Marelli control unit.
Operation / operating principle
Inductive sensor: sinusoidal-type generated volt-
age; two teeth are missing on the flywheel for the
reference position.
Level in wiring diagram:revolution sensor
Location:

• Sensor: front left side of the engine,

under the generator
• Connector: under the fuel tank, right
side

Electrical characteristics:

• Winding resistance: 650 Ω ± 15% Out-

put alternating voltage, value range:
minimum: 0.5 V - maximum: 5 V

Pin-out:

• PIN 1: Engine revolution sensor posi-

tive signal
• PIN 2: Engine revolution sensor nega-
tive signal
• PIN 3: Revolution sensor anti-jamming
cable
NAVIGATOR: PARAMETERS

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Target engine revs

Example value:1100 +/- 100 rpm
Parameter valid at idle, setting depends especially on engine temperature: the ECU unit will try to keep
the engine running at this revs, acting on the ignition advance.
NAVIGATOR: STATUSES
Synchronisation
Example value:Synchronised / Not synchronised
Indicates if the control unit detects the engine speed sensor signal correctly

DIAGNOSIS
Engine revolution sensor
An interruption in the sensor circuit has been detected, from PIN 25 to PIN 35 of connector A (BROWN)
Check the sensor connector and the injection control unit connector A (BROWN): it they are not OK,
restore. If OK, check continuity of the two cables leading to PINS 25 and 35 of the control unit connector:
if there is not continuity, restore the cable harness; if there is continuity, check the interruption on the
sensor and replace it.
WARNING If the electric circuit is short-circuited, no error is displayed. Check the sensor electrical
specifications: If they are not correct, replace the sensor. If correct, check supply insulation and ground
connection insulation of both cables. Perform the tests from the sensor connector towards the sensor.
If they are not OK, restore the cable harness or replace the sensor. If OK, perform the tests for pins 25
and 35 of the Marelli control unit connector A (BROWN) towards the cable harness.
Air gap value:
Place the sensor plus the corresponding spacers; the air gap should be between 0.7 and 0.9 mm (0.027
- 0.035 in).

Throttle position sensor

Function
In charge of telling the control unit the position of
the throttle valves.
Operation / Operating principle
The throttle valve position sensor works as a var-
iable resistance according to the throttle rotation.
Level in electrical circuit diagram:Throttle and
idle motor
Location:

• sensor: on the right cylinder throttle

body
• connector: on the potentiometer

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Electrical characteristics:

• PINS A-C: throttle closed approx. 2.5

kOhm; throttle open approx. 1.5 kOhm.
• PINS A-B: approx. 1.1 kOhm

Pin-out:

• PIN A: ground connection

• PIN B: supply voltage +5V
• PIN C: potentiometer signal

THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION
TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM
THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE
"MAIN" CABLE HARNESS AND INTO THE CONNECTOR/COMPONENT.
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROU-
BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK
AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
AXONE: FUEL INJECTION SYSTEM
AXONE: PARAMETERS
Throttle
Example value: 4.9°

AXONE: STATUSES
Throttle position
Example value:Released/Pressed/Full load
Indicates if the throttle potentiometer is open or closed in the released position.

AXONE: ELECTRICAL ERRORS

Throttle actuator position sensor P0120
Example value:open circuit, shorted to positive / shorted to negative.
Error cause

• If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 3 of
connector A (BROWN).
• If shorted to negative: voltage equal to zero has been detected.

Troubleshooting

• Circuit is open, shorted to positive: check the injection control unit connector and the sensor
connector: if they are not OK, restore; if they are OK, check continuity between PIN 3 of
connector A (BROWN) and PIN C of the sensor (red cable): if there is not continuity, restore
the cable harness; if there is continuity, check continuity of the sensor between PIN A and
PIN C: if there is not continuity, replace the potentiometer; if there is continuity, check the

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resistance. If resistance is over 2.5 kOhm, it means the red cable is shorted to positive and
the cable harness should be restored
• shorted to negative: disconnect the sensor connector and check the ground insulation of the
red cable (from throttle sensor connector or control unit connector): if there is continuity to
ground, restore the cable harness; if it is ground insulated, the resistance between PIN A
and PIN C is below 1.3 kOhm; therefore, the throttle body should be replaced

AXONE: ADJUSTABLE PARAMETERS

Throttle position autodetection: It allows the control unit to detect the closed throttle position; just
press the Enter key.
Self-adjustable parameters reset: Lambda probe self-adaptability parameters reset: operation to be
carried out after the throttle body is cleaned or in the case a new engine, a new lambda probe or a new
injector is fitted, or the correct operation of the injection system or the valves is restored.

AXONE: RESET PROCEDURE

Once the throttle body or the injection control unit is replaced, it is necessary to connect to the diagnosis
instrument selecting FUEL INJECTION and carry out the operation: Throttle positioner autodetection.

Engine temperature sensor

Function
tells the engine temperature to the control unit so
as to optimise its operation.
Operation / Operating principle
NTC type sensor (resistance sensor, inversely
variable with temperature).
Level in electrical circuit diagram:Temperature
sensors
Location:

• Sensor: within the engine "V"

• Connector: on the sensor

Electrical specifications:

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

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

Pin-out:

• PIN 1: Ground connection

• PIN 2:0-5 V signal

THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION
TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM
THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE
"MAIN" CABLE HARNESS AND INTO THE CONNECTOR/COMPONENT.
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROU-
BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK
AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
AXONE: FUEL INJECTION SYSTEM
AXONE: PARAMETERS
Engine temperature
In case of recovery, this value is set by the control unit.

AXONE: ELECTRICAL ERRORS

engine temperature sensor P0115 - open circuit, shorted to positive / shorted to negative.
Error cause

• If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 5 of
connector A (BROWN).
• If shorted to negative: voltage equal to zero has been detected at PIN 5 of the BROWN
connector.

Troubleshooting

• If the circuit is open, shorted to positive: check the sensor connector and the Marelli control
unit connector. If they are not OK, restore the cable harness; if OK, check the continuity of
the sensor; if it is not OK, replace the sensor; if it is OK, check continuity between PIN 5 of
the BROWN connector and PIN 2 of sensor: restore cable harness if there is not continuity;
if it is OK, reconnect the control unit connector and, with key set to key ON, check the
continuity between the sensor connector PIN 1 and the vehicle ground connection: if there
is not continuity, restore the cable harness; if there is continuity, it means that the cause of
the error is that the cable is shorted to positive and now the cable harness between the
BROWN PIN 5 and PIN 2 of the sensor should be restored. If the air temperature sensor

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error is displayed at the same time, this means that the grey cable common for both sensors
is shorted to positive.
• If shorted to negative, check sensor correct resistance: if resistance is null, replace the sen-
sor; if resistance is correct, it means that the orange cable has ground connection: restore
the cable harness.

NOTES No error is detected if the sensor does not work correctly or the control unit connector
or sensor terminals are rusty: then check through Navigator if the temperature indicated is the
same as the engine temperature. Check also that the sensor electrical characteristics are ob-
served: replace the sensor if not OK; if it is OK, check the sensor connector and the Marelli
control unit connector

Air temperature sensor

Function
It tells the control unit the intake air temperature in
order to calculate oxygen presence so as to opti-
mise the petrol quantity necessary for correct com-
bustion.
Operation / operating principle
NTC type sensor (resistance sensor, inversely
variable with temperature).
Level in wiring diagram:Temperature sensors
Location:

• sensor: in front of the filter casing

• connector: on the sensor

Electrical characteristics:

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

Pin-out:

• PIN 1: Ground connection

• PIN 2: 0-5 V signal

THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION
TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM

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THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE
"MAIN" CABLE HARNESS AND INTO THE CONNECTOR/COMPONENT.
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROU-
BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK
AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
AXONE: FUEL INJECTION SYSTEM
AXONE: PARAMETERS
Air temperature
In case of failure, 25°C is set as temperature

AXONE: ELECTRICAL ERRORS

air temperature sensor P0110 - open circuit, shorted to positive / shorted to negative.
Error cause

• If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 14 of
the BROWN connector.
• If shorted to negative: voltage equal to zero has been detected at PIN 14 of the BROWN
connector

Troubleshooting

• If the circuit is open, shorted to positive: check the sensor connector and the Marelli control
unit connector. If they are not OK, restore the cable harness; if OK, check the continuity of
the sensor; if it is not OK, replace the sensor; if it is OK, check continuity between PIN 14
of the BROWN connector and PIN 2 of sensor: restore cable harness if there is not continuity;
if it is OK, reconnect the control unit connector and, with key set to key ON, check the
continuity between the sensor connector PIN 1 and the vehicle ground connection: if there
is not continuity, restore the cable harness; if there is continuity, it means that the cause of
the error is that the cable is shorted to positive and now the cable harness between the
BROWN PIN 14 and PIN 2 of the sensor should be restored. If the engine temperature
sensor error is displayed at the same time, this means that the grey cable common for both
sensors is shorted to positive.
• If shorted to negative, check sensor correct resistance: if resistance = 0, replace the sensor;
if resistance is correct, it means that the pink/black cable has ground connection: restore
the cable harness

NOTES No error is detected if the sensor does not work correctly or the control unit connector
or sensor terminals are rusty: then check through Navigator if the temperature indicated is
plausible in relation to the ambient temperature. Check also that the sensor electrical charac-
teristics are observed: replace the sensor if not OK; if it is OK, check the sensor connector and
the Marelli control unit connector.

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Lambda sensor
Function
In charge of telling the control unit whether the
mixture is lean or rich.
Operation / Operating principle
The Marelli injection control unit reads and inter-
prets a voltage generated by the difference in oxy-
gen content between the exhaust fumes and the
ambient. It does not require an external supply
source but, in order to work properly, it should
reach a high operating temperature: that is why
there is a heating circuit inside.
Level in electrical circuit diagram:Oxygen sen-
sor
Location:

• sensor: exhaust pipe

• Connector: near the probe

Electrical characteristics:
Heater circuit: 12 -14 Ω at 20 °C (68 °F)
Pin-out:

1. Sensor signal + (black wire)

2. Sensor signal - (grey wire)
3. Heater ground connection (white)
4. Heater power supply (white)
AXONE: PARAMETERS
Lambda probe
Example value: 0 - 1000 mV
If there is a short circuit at + 5 V or above, the value read is approx. 5.000 mV. If there is a short circuit
to ground instead, the value read is equal to 0 mV and the Lambda Sensor Correction parameter shows
25%: no error is displayed, though.
Lambda sensor correction
example value: 1.00
In closed loop, the value must be close to 0 % (values not within the +10 % and -10 % range may
indicate a fault): In an open circuit, the lambda probe signal is too low. Therefore, the control unit takes
it as a lean mixture condition and will try to enrich it. The value read will be +25%.
NAVIGATOR: STATUSES
Lambda check

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Example value: Open loop / Closed loop

Closed loop indicates that the control unit is using the lambda probe signal to keep the combustion as
close as possible to the stoichiometric value.

AXONE: ELECTRICAL ERRORS

Lambda probe P0130 - Shorted to positive.
Error cause

• Excessive voltage (battery voltage) has been detected at PINS 32 and 22 of the BLUE
connector.

Troubleshooting

• shorted to positive: with the key set to ON, disconnect the sensor connector and measure
voltage at PIN 1 on the cable harness side (white/yellow cable): if there is voltage (5 or 12
V), restore the cable harness; it there is no voltage, measure voltage at PIN 2, cable harness
side, (green/white cable) and if there is voltage, restore the cable harness; if there is no
voltage, replace the lambda probe

Lambda probe heating P0135 - shorted to positive / open circuit, shorted to negative.
Error cause

• If shorted to positive: excessive voltage has been detected at PIN 11 of the BLUE connector.
• If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 11
of the BLUE connector

Troubleshooting

• shorted to positive: disconnect the probe connector and check the sensor correct resistance:
replace the sensor if not OK; if it is OK, restore the cable harness.
• if the circuit is open, shorted to negative: check the continuity from probe connector (PIN 3
and 4) towards the probe: if not OK, replace the probe; if it is correct, check the sensor
connector and the Marelli control unit connector. If not OK, restore. If OK, and with key set
to ON and sensor connector disconnected, check if there is battery voltage at PIN 4: if not
OK, check the red/black cable (cable harness side) between the probe connector and the
auxiliary injection relay (No. 29 in the wiring diagram, placed under the saddle, rear side, in
the auxiliary fuses/relays box, close to the fuses, in the row towards the rear; CHECK, how-
ever, the identification of the relay with the colour of the cables). If there are also coil and
injector errors, check that relay and its excitation and power line; if there is voltage at PIN
4, check the white cable ground insulation, cable harness side (PIN 3): if it is not OK, restore
the cable harness. If OK, check continuity of the white cable, cable harness side (between
PIN 3 of the sensor connector PIN 3 and PIN 11 of the BLUE connector) and restore the
cable harness.

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Injector

Function
To supply the correct amount of petrol at the right
timing.
Operation / Operating principle
Injector coil is excited for the petrol passage to
open.
Level in wiring diagram:Coils and injectors
Location:

• on the throttle bodies

• connector: on injector

Electrical characteristics:14.8 Ohm +/- 5% (at

20 °C)
Pin-out:
"+": Supply:
" ": Ground connection

THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION
TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM
THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE
"MAIN" CABLE HARNESS AND INTO THE CONNECTOR/COMPONENT.
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROU-
BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK
AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
AXONE:FUEL INJECTION SYSTEM
AXONE: PARAMETERS
Injection time

AXONE: ACTIVATIONS
Left injector: operation for 4 ms, 5 times
The auxiliary injection relay (No. 29 in the wiring diagram, placed under the saddle in the fuse box) is
energised for 5 seconds and the grey/red cable of the injector is closed to ground for 4 ms per second.
Disconnect the four-way connector of the fuel pump to be able to hear the relay and injector activation.
The continuity of the wiring is necessary for correct activation: no error indications are displayed in case
of lack of activation

AXONE: ELECTRICAL ERRORS

Left cylinder injector P0201 - shorted to positive / shorted to negative / open circuit.
Error cause

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 BELLAGIO Electrical system

• If shorted to positive: excessive voltage has been detected at PIN 28 of the BROWN con-
nector.
• If shorted to negative: no voltage has been detected.
• If the circuit is open: an interruption has been detected.

Troubleshooting

• Shorted to positive: disconnect the injector connector, take the key to ON and check if there
is voltage on the grey/red cable: if there is voltage, restore the cable harness. If there is no
voltage, replace the injector.
• Shorted to negative: disconnect the injector connector, take the key to ON and check if the
grey/red cable has continuity to the ground connection: if there is continuity to ground, re-
store the cable harness; if there is not continuity, replace the injector
• the circuit is open: check the component correct electrical characteristic: if it is not the correct
one, replace the component; if it is correct, check the connector on the component and the
Marelli control unit connector: If they are not OK, restore. If OK, check cable continuity be-
tween PIN 28 of the BROWN connector and the component PIN - and restore the cable
harness.

AXONE: ACTIVATIONS
Right injector: operation for 4 ms, 5 times
The auxiliary injection relay (No. 29 in the wiring diagram, placed under the saddle in the fuse box) is
energised for 5 seconds and the blue/red cable of the injector is closed to ground for 4 ms per second.
Disconnect the four-way connector of the fuel pump to be able to hear the relay and injector activation.
The continuity of the wiring is necessary for correct activation: no error indications are displayed in case
of lack of activation

AXONE: ELECTRICAL ERRORS

Right injector - shorted to positive / shorted to negative / open circuit.
Error cause

• If shorted to positive: excessive voltage has been detected at PIN 37 of the (BROWN) con-
nector.
• If shorted to negative: no voltage has been detected.
• If the circuit is open: an interruption has been detected.

Troubleshooting

• Shorted to positive: disconnect the injector connector, take the key to ON and check if there
is voltage on the blue/red cable: if there is voltage, restore the cable harness. If there is no
voltage, replace the injector.
• Shorted to negative: disconnect the injector connector, take the key to ON and check if the
blue/red cable has continuity to the ground connection: if there is continuity to ground, re-
store the cable harness; if there is not continuity, replace the injector.

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 Electrical system BELLAGIO

• the circuit is open: check the component correct electrical characteristic: if it is not the correct
one, replace the component; if it is correct, check the connector on the component and the
Marelli control unit connector: If they are not OK, restore. If OK, check cable continuity be-
tween PIN 37 of the BROWN connector and the component PIN - and restore the cable
harness.

Fuel pump

Petrol pump:
Input: 3.5 A (to be measured between pins 1 and
2 with 12V voltage)
The low fuel warning light turns on with values over
230 Ohm.

Coil

Function
It controls the ignition spark plug in order to gen-
erate the fuel ignition spark.
Operation / operating principle
With inductive discharge: 2 coils with double sec-
ondary circuit (Twin spark)
Level in wiring diagram:Coils and injectors
Location:

• Under the tank, right and left side

• connector: on the coil

Electrical characteristics:

• Primary winding resistance: 570

mOhm ± 50 mOhm
• Secondary winding resistance: 7330
Ohm ± 500 Ohm

Measured at 23°C ± 5°
Pin-out:

• PIN 1: Circuit earthing

• PIN 2: Power (battery voltage)

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THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION
TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM
THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE
"MAIN" CABLE HARNESS AND INTO THE CONNECTOR/COMPONENT.
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROU-
BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK
AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
AXONE: ACTIVATIONS
Left coil:
The auxiliary injection relay (No. 29 in the wiring diagram, placed under the saddle, rear side, in the
auxiliary fuses/relays box, in the rear row close to the fuses; CHECK, however, the identification of the
relay with the colour of the cables) is energised for 5 seconds and the green/orange cable of the coil is
closed to ground for 2 ms per second. Disconnect the 4-way connector of the fuel pump to be able to
hear the relay and injector activation. The continuity of the wiring is necessary for correct activation: no
error indications are displayed in case of lack of activation

AXONE: ELECTRICAL ERRORS

Left coil - shorted to positive / open circuit, shorted to negative
Error cause

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

Troubleshooting

• Shorted to positive: disconnect the coil connector, set the key to ON, activate the coil with
Axone and check voltage at connector PIN 2: if there is voltage, restore the cable harness;
if voltage = 0, replace the coil.
• If the circuit is open, shorted to negative: check the coil connector and the Marelli control
unit connector. If not OK, restore; if everything is OK, check cable continuity between the
two cable terminals. If there is no continuity, restore the cable harness; if there is cable
continuity, with key set to ON, check the cable earth insulation (from coil connector or control
unit connector). If not OK, restore the cable harness.

AXONE: ACTIVATIONS
Right coil:
The auxiliary injection relay (No. 29 in the wiring diagram, placed under the saddle, rear side, in the
auxiliary fuses/relays box, in the rear row close to the fuses; CHECK, however, the identification of the
relay with the colour of the cables) is energised for 5 seconds and the sky blue/green cable of the coil
is closed to ground for 2 ms per second. Disconnect the 4-way connector of the fuel pump to be able

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 Electrical system BELLAGIO

to hear the relay and injector activation. The continuity of the wiring is necessary for correct activation:
no error indications are displayed in case of lack of activation

AXONE: ELECTRICAL ERRORS

Right coil - shorted to positive / open circuit, shorted to negative.
Error cause

• If shorted to positive: excessive voltage has been detected at PIN 10 of the BROWN con-
nector.
• If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 10
of the BROWN connector.

Troubleshooting

• Shorted to positive: disconnect the coil connector, set the key to ON, activate the coil with
Axone and check voltage at connector PIN 2: if there is voltage, restore the cable harness;
if voltage = 0, replace the coil.
• If the circuit is open, shorted to negative: check the coil connector and the Marelli control
unit connector. If not OK, restore; if everything is OK, check cable continuity between the
two cable terminals. If there is no continuity, restore the cable harness; if there is cable
continuity, with key set to ON, check the cable earth insulation (from coil connector or control
unit connector). If not OK, restore the cable harness.

Engine oil pressure sensor

Function:Indicates the instrument panel if there is

enough oil pressure (0.35 +/- 0.2 bar) (5.1 +/- 2.9
PSI) in the engine.
Operation / Operating principle: normally closed
switch. With oil pressure above 0.35 +/-0.2 bar (5.1
+/- 2.9 PSI), open circuit.
Level in wiring diagram:fuel reserve and oil pres-
sure.
Location:

• Sensor: in between the engine "V", a

little to the left
• connector: on the sensor.

Electrical characteristics:

• With engine off: closed circuit (continu-

ity).

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 BELLAGIO Electrical system

• With engine started: open circuit (infin-

ite resistance).

Pin-out:

• PIN 1: voltage 12V

Instrument panel
Oil sensor failure DSB 07
Error cause

• An oil sensor failure is signalled when, with engine off, it is detected that the sensor circuit
is open. The test is performed only once when the key is set to ON. This error is signalled
by the bulb icon and the general warning light turns on as well.

Troubleshooting

• Check the sensor connector and the instrument panel connector (PIN 17): If not OK, restore.
If OK, check the continuity of the purple cable between the sensor connector and the in-
strument panel connector PIN 17: if not OK, restore the cable harness; if OK, replace the
sensor.

Oil pressure failure DSB 08

Error cause

• An oil sensor failure is signalled when, with engine running, it is detected that the sensor
circuit is closed. This error is signalled by the bulb icon and the general warning light turns
on as well.

Troubleshooting

• Detach the sensor connector and check the purple cable is ground insulated: if there is
continuity to ground, restore the cable harness; if it is ground insulated, replace the switch.
It this error persists, use a pressure gauge to check the pressure of the oil in the engine
circuit

Neutral sensor

Function
it tells the gear position to the control unit: in neutral or in gear.
Operation / Operating principle
for gear in neutral, the circuit is closed to ground connection: then, via CAN, the control unit sends the
signal to the instrument panel which turns on the neutral speed warning light.
Level in electrical circuit diagram:start-up enabling switches
Location:

• Sensor: rear / upper side of the gearbox

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• Connector: on the sensor

Electrical characteristics:
• Gear in neutral: closed circuit (0 V on wire from control unit to sensor / switch in continuity).
• Gearshift engaged: open circuit (12 V on wire from control unit to sensor / open switch,
infinite resistance)
Pin-out:
• PIN 1: Voltage 12V
NAVIGATOR: STATUSES
Gear in neutral
Example value:yes/no
DIAGNOSIS
• Indication on the instrument panel always gear engaged: check the control unit connector
and the sensor connector: if they are not OK, restore the cable harness; if OK, disconnect
the connector and, with gear in neutral, check continuity to ground of the terminal, sensor
side: if there is not continuity, replace the sensor (after checking cable harness continuity
on the sensor side and the correct mechanical position); if there is, check cable continuity
between the sensor connector and PIN 23 of the BROWN connector: if there is no continuity,
restore the cable harness. If there is, replace the instrument panel if the vehicle performance
is correct (the engine starts with gear in neutral but the neutral warning light is off) or replace
the control unit if the vehicle performance is not correct (the engine does not start with gear
in neutral).
• Indication on the instrument panel always gear in neutral: disconnect the terminals from the
sensor and check if there is continuity with ground connection at PIN toward the sensor, with
gear engaged: if there is continuity, replace the sensor. If it is ground insulated, it means
that the grey/black cable from PIN 1 of the sensor to PIN 23 of the BROWN connector is
shorted to ground: restore the cable harness.

Clutch lever sensor

Function
It tells the clutch lever position to the control unit.
Operation / operating principle
In order to start the engine, pull the clutch also with the gear in neutral.
Level in wiring diagram:Start-up enabling switches.
Location:
• sensor: under clutch lever
• connector: on the sensor
Electrical characteristics:

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 BELLAGIO Electrical system

• Clutch pulled: closed circuit (continuity)

• Clutch released: open circuit (infinite resistance)

Pin-out:

1. Voltage 12V
2. Ground connection

Side stand sensor

Function
It tells the side stand position to the control unit.
Operation / Operating principle
If the gear is engaged and the side stand is unfolded, and therefore the circuit is open, the control unit
does not enable vehicle start-up or shuts off the engine if it is rotating.
Level in electrical circuit diagram:Start-up enabling switches
Location:

• sensor: on side stand supporting plate

• Connector: left side, near the starter motor

Electrical characteristics:

• Side Stand Up: closed circuit (continuity)

• Side Stand Down: open circuit (infinite resistance)

Pin-out:

1. Ground connection
2. Voltage 12 V (brown, sensor side)

AXONE: STATUSES
Side stand
Example value:retracted / extended
DIAGNOSIS

• Indication on Axone always EXTENDED: check the side stand sensor connector and the
ECU connector: if they are not OK, restore; if OK, disconnect both terminals from the sensor
and check continuity to ground of PIN 1 (blue/green, cable harness side): if there is not
continuity, restore the cable harness; if there is, check continuity of the green/brown cable:
if it is not OK, restore; if OK, replace the sensor.
• Indication on Axone always RETRACTED: disconnect the terminals from the sensor and
check if there is continuity between the two PINS, with stand down: if there is continuity,
replace the sensor; if the circuit is open, it means that the brown/green cable (cable harness
side) from PIN 2 of the sensor to PIN 38 of the BLUE connector is shorted to ground: restore
the cable harness

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Air temperature sensor - instrument panel

Function
It tells the ambient air temperature to the instru-
ment panel.
Operation / operating principle
NTC type sensor (resistance sensor, inversely
variable with temperature).
Level in wiring diagram:Temperature sensors
Location:

• sensor: on the front headlamp support,

right side
• connector: under the instrument panel

Electrical characteristics:

• Resistance at 0°C: 32.5 kOhm +/- 5%

• Resistance at 25°C: 10.0 kOhm +/- 5%

Pin-out:

1. Voltage 5V
2. Ground connection
THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION
TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM
THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE
"MAIN" CABLE HARNESS AND INTO THE CONNECTOR/COMPONENT.
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROU-
BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK
AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
Instrument panel
Air temperature sensor failure DSB 06
Error cause
• An oil sensor failure is signalled when it is detected that the sensor circuit is open or shorted
to positive
Troubleshooting
• Check the sensor connector and the instrument panel connector (PINS 10 and 18): If they
are not OK, restore. If OK, check continuity of the pink cable between the sensor connector
and the instrument panel connector PIN 10: if it is not OK, restore the cable harness; if OK,
check the correct sensor resistance: if it is not OK, replace the sensor; if it is OK, check
continuity of the brown cable between the sensor connector and PIN 18 of the instrument

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panel connector: If not OK, restore the cable harness; if OK, with key set to ON, check if
there is voltage at the sensor connector PIN 1: if there is no voltage, replace the instrument
panel; if there is approximately 12V, restore the cable harness (there is a short circuit in the
battery). If there is 5V voltage, connect a 10 kOhm resistance to PIN 1 of the sensor con-
nector and to the vehicle ground connection: if, with key set to KEY ON, the voltage
measured upstream the resistance decreases, replace the instrument panel. If voltage con-
tinues to be approximately 5V, restore the pink cable (there is a short circuit at + 5V).

Notes
If a short circuit to ground is detected at PIN 10 of the instrument panel connector, the display will show
a full scale temperature indication of 60°C
Check the ground insulation of the sensor connector pink cable: if there is a connection, restore the
cable harness; if it is earth insulated, check that sensor resistance is correct: if it is not OK, replace the
sensor; if it is OK, replace the instrument panel.

RUN/STOP switch

Function
It tells the control unit if the driver wishes to enable
engine start-up or to keep the engine running.
Operation / Operating principle
If the driver wants to shut off the engine or to dis-
able engine start-up, the switch should be open,
i.e. the Marelli control unit should not detect volt-
age at PIN 27 of the BLUE connector
Level in wiring diagram:Start-up enabling
switches.
Location:

• Switch: right light switch

• Connector: next to the headstock, right
side

Electrical characteristics:

• STOP position: the circuit is open

• RUN position: closed circuit (continui-
ty)

Pin-out:

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• Sky blue/orange cable (cable harness

side): 0V voltage if engine kill in STOP;
12V if engine kill in RUN.
• Red/black cable (cable harness side):
always 12 V voltage
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROU-
BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK
AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
NAVIGATOR: PARAMETERS
-
AXONE: STATUSES
Run / stop switch
Example value:Run/Stop
DIAGNOSIS
• Indication on Axone always STOP: disconnect the connector and, with the switch set to
RUN, check if there is continuity between the blue/green (PIN 1) cable and the grey/sky blue
(PIN 4) cable (sensor side): if there is not continuity, replace the sensor; if there is, check
the connector. If it is not OK, restore the cable harness; if it is OK, with the key set to ON,
check if there is voltage on the red/black cable (cable harness side). If there is no voltage,
restore the cable harness; if there is, check the ground insulation of the sky blue/orange
cable (cable harness side). if there is continuity to ground, restore the cable harness; if it is
OK, take the key to OFF and check that the BLUE connector is in good conditions and if
there is continuity of the sky blue/orange cable between the connector in question and PIN
27 of the BLUE connector: if not OK, restore the cable harness; if OK, replace the Marelli
control unit
• Indication on Axone always RUN: disconnect the connector and, with the switch set to
STOP, check if there is continuity between the two cables of the switch, PIN 1 and PIN 4
(sensor side). If there is continuity, replace the switch; if there is not, it means that, with the
key set to KEY ON, the sky blue/orange cable is shorted to positive: restore the cable har-
ness

Connectors

ECU
The connectors on the control unit are both black. For the following pin explanation, the cable harness
connectors are the reference:
Engine connector pins (brown)
Pin Use

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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 Not used
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 Not used
18 Not used
19 Not used
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
34 Revolution sensor anti-jamming cable
35 Engine revolution sensor signal
36 Not used
37 Right cylinder injector control
38 Left cylinder coil control

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Vehicle connector pins (blue)

Pin Use
1 Not used
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 Not used
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 Not used
29 CAN - L line (ccm/instrument panel)
30 Not used
31 Not used
32 Oxygen probe power supply
33 Not used
34 Not used
35 Not used
36 Not used

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37 Not used
38 Side stand sensor signal

Dashboard

PIN USE
1 + KEY
2 RIGHT TURN INDICATOR CONTROL
3 HIGH-BEAM LIGHT INPUT
4-
5-
6 K LINE
7-
8 SCROLL
9 FUEL LEVEL SENSOR
10 EXTERNAL AIR TEMPERATURE SENSOR
11 + BATTERY
12 LEFT TURN INDICATOR CONTROL
13 -
14 HAZARD
15 -
16 GENERAL EARTH CONNECTION
17 OIL PRESSURE SENSOR
18 SENSORS EARTH CONNECTION
19 GENERAL EARTH CONNECTION
20 GENERAL EARTH CONNECTION
21 + BATTERY
22 FRONT LEFT TURN INDICATOR ACTUATOR
23 REAR LEFT TURN INDICATOR ACTUATOR
24 -
25 -
26 CAN H LINE
27 -
28 LIGHT RELAY ACTUATOR
29 -
30 TRIP 1 - 2
31 + BATTERY

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32 FRONT RIGHT TURN INDICATOR ACTUA-

TOR
33 REAR RIGHT TURN INDICATOR ACTUATOR
34 -
35 -
36 CAN L LINE
37 -
38 -
39 -
40 TRIP 1

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 INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

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 Engine from vehicle BELLAGIO

Vehicle preparation

• Drain off the engine oil.

• Remove the tank.
• Remove the exhaust system.
• Remove the fork.
• Remove the shock absorber.
• Remove the air filter casing.
• Remove the battery.

• Operating from both sides, undo and

remove the lower screw.

• Operating from both sides, remove the

throttle body covers by sliding them off
from above.

• Operating from both sides, undo and

remove the two screws.

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 BELLAGIO Engine from vehicle

• Operating from both sides, remove the

side plate.

• Remove the throttle body.

Removing the engine from the vehicle

• Operating from both sides, undo and

remove the two screws.

• Disconnect the spark plug tubes.

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• Disconnect the engine temperature

sensor connector.

• Undo and remove the two screws.

• Remove the timing sensor.

• Disconnect the oil pressure sensor.

• Remove the clamp.

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• Disconnect the generator connector.

• Operating on both sides, release the

clamp.
• Disconnect the oil vapour recovery
pipe.
NOTE
UPON REFITTING, ALWAYS REPLACE WITH A NEW
CLAMP.

• Release the clamp and disconnect the

crankcase / timing system vapour re-
covery pipe.

• Slide off the transmission oil breather

pipe.

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• Disconnect the gear in neutral sensor

connector.

• Unscrew and remove the two screws.

• Remove the starter motor protection.

• Disconnect the side stand sensor con-

nector.

• Unscrew and remove the screw.

• Disconnect the earth leads.

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• Disconnect the starter motor connec-

tors.

• Undo and remove the screw.

• Remove the gear transmission lever.

• Unscrew and remove the three screws.

• Remove the clutch control cylinder.
• Lock the plunger using a clamp.

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• Undo and remove the brake control fix-

ing screw.
• Turn the footrest to operate on the en-
gine pin.

• Undo and remove the lower rear pin.

• Slide off the pin from the right side.

• Undo and remove the two rear brake

control screws.

• Working from both sides, undo and re-

move the engine front fixing screw.

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 BELLAGIO Engine from vehicle

• Unscrew and remove the upper rear

pin nut.
• Remove the pin from the opposite side.

• Lift the chassis.

Installing the engine to the vehicle

For refitting, follow the operations in reverse order observing the tightening torque.

ENG VE - 83

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 INDEX OF TOPICS

ENGINE ENG

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 BELLAGIO Engine

Gearbox

Diagram

KEY:
1. Ball bearing
2. Circlip

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 Engine BELLAGIO

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

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 BELLAGIO 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

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Removing the gearbox

• Remove the starter motor.

• Make sure the transmission is in idle.

• Unscrew and remove the breather

pipe.

• 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.

• Unscrew and remove the two screws.

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 BELLAGIO Engine

• Unscrew and remove the screw.

• Remove the gearbox.

See also
Removing the
starter motor
Replacement

Gearbox shafts

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

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• From the outside, slide off the thrust

cylinder and collect the O-Ring and the
washer.

• Remove the thrust bearing and the

washer.

• 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

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• Open the gearbox using the specific

tool.

Specific tooling
05.91.25.30 Gearbox opening

• Release the spring.

• Pressing the selector, slide off the

whole transmission lever.

• Unscrew and remove the threaded ref-

erence pin.

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• Use rubber bands to tie down the trans-

mission shaft unit and extract it.

• 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.

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• Replace bearings if necessary and re-

move the clutch shaft.

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Removing the primary shaft

• Remove the main shaft.

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

• 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.

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• Remove the gear of the third and fourth

gears.

• 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.

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Removing the secondary shaft

• Remove the transmission shaft.

• Operate on the shaft from the grooved
side.

• Remove the shoulder washer.

• Remove the gear of the second gear

and collect the ball bearing cage and
the shoulder washer.

• Remove the circlip.

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• Remove the gear of the sixth gear.

• 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.

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• Remove the circlip.

• 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).

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• 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).

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.

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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.

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• 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.
See also
Disassembling the
clutch shaft

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.

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See also
Disassembling the gearbox

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.

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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

The alternator is made of two elements:

The stator that is fixed on the timing system cover
and the rotor that is fitted on the crankshaft.

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• Unscrew the four screws and remove

the alternator cover.

• Remove the gearbox.

• Lock the rotation of the engine flywheel
using the appropriate locking tool.

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

• Remove the rotor centre sealing nut.

• Remove the stator unscrewing the

three fixing screws.

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• Remove the washer and take out the

rotor.

IN ORDER TO PREVENT DEMAGNETISATION INTRO-

DUCE THE ROTOR AGAIN ON THE STATOR PREVIOUSLY
REMOVED.

• Remove the cotter.

Starter motor

Removing the starter motor

• Undo and remove the two screws and

collect the washers.

• Slide off the starter motor.

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 Engine BELLAGIO

Clutch side

Disassembling the clutch

• Remove the gearbox from the engine.

• Remove the pressure plate disc cover.

• 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 crown gear fitted on
the engine flywheel, collecting the
washers.

• Remove the start-up sprocket gear.

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 BELLAGIO Engine

Extract from the inside of the engine flywheel:

• the clutch plate.

• The intermediate plate.

• The second clutch plate.

• Remove the tool used to compress the clutch springs.

Specific tooling
30.90.65.10 Tool for clutch fitting

• The pressure plate disc with springs.

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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).

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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

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• 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.

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• 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.

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• 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.

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• 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.

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• 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.

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• 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

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 Engine BELLAGIO

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)

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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.

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• 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

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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.

• 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.

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• 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

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Chain removal

• Remove the engine assembly.

• Remove the alternator.
• Unscrew the fourteen screws (1 - 2 - 3).

• Remove the timing system cover.

• Collect the gasket.

• 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

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• Unscrew the central sealing nut of the

camshaft gear and collect the washer.

• Slide off the spacer from the crank-

shaft.

• 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.

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• 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.

• Remove the rocking lever support.

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• 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

Removing the phonic wheel

• Remove the timing chain.

• Slide off the tone wheel and collect the
plug.

See also

Chain removal

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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.

• Remove the camshaft.

See also

Chain removal
Removing the phonic wheel
Removing the tappets
Removing the rods

Installing the camshaft

NOTE

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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".

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.

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• 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.

• 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.

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• Introduce the belleville spring and the

nut to fasten the camshaft gear.

• Introduce the washer and the nut to

fasten the crankshaft gear.

• Turn the oil pump shaft and introduce

the gear pulling woodruff key.

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• 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 rockers

and valves of 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
981001 Graduated dial hub
19.92.96.00 Graduated dial to control ignition
timing
• With a screw, fasten the specific arrow
to the threaded hole to the left of the
crankcase.

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• 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.

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• 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 rockers and valves (intake 0.10 mm (0.0039 in), exhaust 0.15 mm (0.0059
in).
• Remove the graduated dial hub, the graduated dial, the arrow, the dial gauge support and
the gauge itself.
• Refit the spark plugs and finish the refit.

Specific tooling
981001 Graduated dial hub
19.92.96.00 Graduated dial to control ignition timing

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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.

• Place the sensor on the timing system

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

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 BELLAGIO Engine

• 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.

• Slide off the cylinder from the stud

bolts, paying attention not to damage
the piston.

See also
Removing the
cylinder head

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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.

• Mark the piston crown on the exhaust

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

See also
Removing the
cylinder

Fitting the piston

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

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 BELLAGIO Engine

• 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.

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

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 Engine BELLAGIO

• 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.

• Place the gasket on the cylinder base.

• Fit the head.

See also
Fitting the piston
Installing the
cylinder head

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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

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• 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.

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 BELLAGIO Engine

• Replace the gasket and install the

head cover.

See also
Installing the valves
Installing the
head cover

Installing the head cover

• Replace the gasket and install the

head cover.

• Tighten the eight screws operating di-

agonally.

Crankcase - crankshaft

Removing the crankshaft

• Remove the connecting rods.

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 Engine BELLAGIO

• 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.

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 BELLAGIO Engine

• 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

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 Engine BELLAGIO

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)

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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

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 Engine BELLAGIO

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.

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 BELLAGIO Engine

• 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.

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• 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.
• Collect the gasket.

DURING REFITTING REPLACE THE GASKET WITH A NEW

ONE OF THE SAME TYPE.

• If necessary, it is possible to remove

the components shown on the figure.

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 INDEX OF TOPICS

POWER SUPPLY P SUPP

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 Power supply BELLAGIO

Circuit diagram

Key:

1. Fuel tank
2. Complete fuel pump
3. Flanged screw
4. Three-way joint
5. Joint
6. Clamp
7. Throttle body
8. Fuel pipe

Injection

Removing the throttle body

• Remove the air filter casing.

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 BELLAGIO Power supply

• Remove the injector connectors.

• Remove the TPS connector from the

left throttle body.

• Operating on both sides, undo and re-

move the three screws form the intake
manifold.

• Remove the throttle cable and starter.

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• Remove the throttle body from one

side of the vehicle.

Cylinders synchronisation

Procedure to control and set the throttle body

ENGINE OFF - KEY OFF

• Connect the vacuometer.

• Connect the diagnosis instrument to
the diagnosis connector and the bat-
tery.
• Disconnect the throttle body dipstick
(1) from the left (on the potentiometer
side).
• On the left throttle body, using the
throttle adjustment dowel, adjust the
throttle potentiometer to 3.6° (+/- 0.1°).

Note: this value corresponds to a reading of 536

mV (+/- 20 mV)
BEFORE DISCONNECTING THE POTENTIOM-
ETER, TURN THE KEY TO "OFF".

ENGINE ON (take the engine temperature at least

50 °C / 122 °F)
• KEY ON - COMPLETELY CLOSE the
BY-PASS screws.
• Level the depression in the right cylin-
der by the throttle adjustment dowel (2)
(WITH DIPSTICK (1) DISCONNEC-
TED).
• Connect the throttle body dipstick (1),
then check OUT-OF-IDLE (2000/3000
RPM) the balance of both cylinders de-

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 BELLAGIO Power supply

pression. If they are not balanced, ad-

just the balance screw (3) (left side) to
level both cylinders.

DISCONNECT THE VACUOMETER (IMPORTANT)

ENGINE TEMPERATURE SHOULD RANGE BETWEEN 70 °C (158 °F) AND 80 °C (176 °F)

• By means of the by-pass screws, adjust idle at 1100 +/- 80 rpm paying attention to the value
on the diagnosis instrument.
• Check upstream of the exhaust ends that the CO value of the two cylinders is between 0.7
and 1.2%. If one of the two values is slightly off the range, it is possible to carry out small
adjustments using the cylinder by-pass, keeping the minimum idle rpm at the prescribed
value.

NOTE: if after this procedure, idle is not within the indicated range, check potentiometer connected to
the digital tester, completely closing the throttle on the duct (throttle angle 0°). The value on the tester
must be 150 mV +/-15 mV; if not, refit the potentiometer to find value 150 mV.

SETTING SUMMARY CHART

Specification Desc./Quantity
Throttle minimum position 3.6° +/- 0.1° (value in mV: 536 +/- 20 mV)
By-pass adjustment Balance both cylinders, approximately 1 turn (the value may
vary from vehicle to vehicle).
Nominal rpm 1100 +/- 80 rpm with engine temperature of at least 80 °C (176
°F).

Co rate adjustment

• Remove the saddle.

• Connect a vacuometer to the sockets on the intake manifolds.
• Using the appropriate cables, connect the AXONE diagnosis instrument to the diagnosis
socket and to the vehicle battery (not to another battery).
• Always connect the positive clamp first and then the negative one.
• Turn on the AXONE pushing the button 'ON/OFF'
• Using the side arrows select the menu 'Self-diagnosis'.
CAUTION
IN ORDER TO ACCESS THE 'SELF-DIAGNOSIS' FUNCTIONS THE OBD MODULE MUST BE FIT-
TED ON THE BACK OF THE AXONE.

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• On the next screens select: vehicle

brand (MOTOGUZZI), model (if the
model Bellagio is not available, choose
Breva V1100 avoiding throttle position
autodetection), engine, system type
(injection system software), chassis in-
itial numbers, type of electronic control
unit fitted.
• Turn the ignition to "ON", AXONE is
connected to the control unit.
• Select the throttle potentiometer pa-
rameter.
• Disconnect the stem (1) from the left
side throttle body releasing the snap
ring (2).
• On the left throttle body, using the
throttle adjustment dowel (3), adjust
the throttle potentiometer to 3.6° (+/-
0.1°) visible on AXONE.

This value corresponds to a reading of 536 mV (+/-

20 mV)

USE AN ALLEN WRENCH TO WORK ON THE ADJUST-

MENT DOWEL (3).
CAUTION
BEFORE DISCONNECTING THE POTENTIOMETER, TURN
THE KEY TO "OFF".

• Connect the stem (1) of the left side

throttle body.
• Start the engine and let the tempera-
ture reach 50 °C (122 °F) (visible on
AXONE) after selecting the engine
temperature parameter.
• Close by-passes (4) completely on
both sides.
• Disconnect the stem (1) from the left
side throttle body.

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• Balance the depression on the right

cylinder using the throttle adjustment
dowel (5).
• Connect the stem (1) of the left side
throttle body.

• Check the depression balance be-

tween the two cylinders twisting the
throttle grip a little (approximately
2000/3000 RPM). In case of imbal-
ance, use the adjustment screw (6) to
level the depression.

• Disconnect the vacuometer.

• Engine temperature should range between 70 °C (158 °F) and 80 °C (176 °F).
• Open both by-passes (4) gradually so as to take the minimum idle rpm to 1100 +/- 80, visible
on AXONE after selecting the engine revs parameter, keeping depression balanced.
• Check upstream of the two outlet terminals that the CO value of the two cylinders is between
0.7 and 1.2%. If one of the two values is slightly off the range, it is possible to carry out small
adjustments using the relative cylinder by-pass, keeping the minimum idle rpm at the pre-
scribed value.
• Turn off and disconnect Axone.
CAUTION
AXONE MAY GET LOCKED DURING OPERATION.
IN THIS CASE TURN THE IGNITION KEY TO 'OFF', TURN OFF AXONE PUSHING 'ON/OFF', DIS-
CONNECT THE UPPER CONNECTOR AND WAIT SOME SECONDS BEFORE CONNECTING IT
TO THE CONTROL UNIT AGAIN.
If after this procedure the idle value is not within
the indicated range, check the potentiometer using
a tester proceeding as follows:
- set the throttle completely closed on the duct
(throttle angle 0°);
- turn the ignition key to "ON";
- place the tester leads on the potentiometer con-
nector between the poles (Q) and (R) and check

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 Power supply BELLAGIO

that the voltage value measured is 150mV +/-

15mV.
- In case the potentiometer reading does not match
the above mentioned value, loosen the two poten-
tiometer fixing screws and place it again correctly.

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 -

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

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Specification Desc./Quantity
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

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

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Specification Desc./Quantity
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
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''

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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
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

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 Power supply BELLAGIO

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 - 158

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 INDEX OF TOPICS

SUSPENSIONS SUSP

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 Suspensions BELLAGIO

Front

Removing the front wheel

• Remove both brake callipers.

• Loosen the screws on the wheel axle

clamps.

• Unscrew and remove the pin.

• Remove the wheel.

• If required, collect the spacers.

Front fork

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Diagram

Key:

1. Fork upper plate

2. TBEI screw
3. Washer
4. Screw
5. Cap
6. Rubber ring
7. Screw
8. Ring nut
9. Spacer
10.Chrome-plated cap
11.Base with headstock
12.Screw

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13.Right adjustment ring nut

14.Screw with OR
15.Complete cap
16.Cap
17.Preload tube
18.Spring
19.Stem
20.Lower bushing
21.Ring
22.Right tube (extension)
23.Lock nut
24.Right pumping member rod (extension)
25.Counter spring
26.Right piston (extension)
27.Right piston ring (extension)
28.Right pin (extension)
29.Calibration tab
30.Nut
31.Bottom valve unit
32.O-ring
33.Adaptor
34.Dust guard
35.Snap ring
36.Sealing ring
37.Cap
38.Upper bushing
39.Right sleeve
40.Screw
41.Washer
42.Screw
43.Left sleeve
44.Left adjustment ring nut (compression)
45.Left pipe (compression)
46.Left pumping member rod (compression)
47.Cap
48.Calibration tab
49.Left pin (compression)
50.Left piston (compression)

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51.Nut
52.Complete right stem
53.Complete left stem
54.O-ring
55.Spring

Removing the fork legs

• Hold the front part of the vehicle with a belt and a hoist.
• Remove the front wheel.

• Unscrew the screws fixing the front

mudguard and remove it.

• Support the stanchion and loosen the

screws on the upper and then the lower
plate.

• Remove the fork stem.

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Draining oil

The vehicle is equipped with a hydraulic telescopic fork with separated shock absorber damping ad-
justment in extension and compression:
The left stem works in extension while the right one in compression.
Although the two stems work in a different mode, their internal components are similar; therefore, oil
drainage and topping up are carried out following the same operations; that is why the following oper-
ations apply to both stems.
CAUTION
DURING OIL DRAINAGE AND REFILLING OPERATIONS, THE STEM AND ITS INNER PARTS
SHOULD BE LOCKED IN A VICE; BE VERY CAREFUL NOT TO DAMAGE THEM BY EXERTING
AN EXCESSIVE FORCE; ALWAYS USE ALUMINIUM JAW CAPS.
Outlet:

• Remove the stem from the fork.

• Place the stem in a vice equipped with
jaws covered in aluminium so as not to
damage the stem.
• With an hexagonal spanner, unscrew
the upper closing cap. Be careful not to
damage the O-ring during removal.
Push the carrying tube inside the wheel
carrier.
• Holding the upper cap with the spanner
used before, loosen the lock nut, using
an hexagonal spanner. Unscrew the
upper cap completely and remove it
from the shock absorber rod end.

• Using an appropriate container, drain

as much as possible the oil contained
in the stem.
• Hold the stem in the vice again and,
holding the preloading tube, loosen the
lock nut partially for discharging the in-
ternal spring.

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• Remove the open washer for releasing

the preloading tube and the spring.

• Remove the preload tube and the

spring.

• Drain the oil from the stem again and

for easy drainage of the oil inside the
shock absorber unit more easily, push
the shock absorber rod to pump oil out.

BY PUMPING OIL OUT OF THE SHOCK ABSORBER USING

THE ROD, AN OIL JET WILL FLOW FROM THE ROD END
DUE TO THE PRESSURE. THEREFORE, IN ORDER TO
AVOID DAMAGE OR INJURIES, POINT THE ROD END TO
AN APPROPRIATE CONTAINER.

• Carefully check each part of the stem and make sure that there are no damaged elements.
• If there are no damaged or worn elements, refill the stem; otherwise, replace the damaged elements.

Disassembling the fork

• Drain out all the oil in the stem.

• Block the wheel holder sleeve with a
vice.
• Unscrew the bottom screw and remove
it together with its gasket.

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• Remove the dust scraper using a

screwdriver as a lever.
CAUTION
BE CAREFUL NOT TO DAMAGE THE SLEEVE RIM AND
THE DUST SCRAPER.

• Remove the locking ring inside the

sleeve using a thin screwdriver.
CAUTION
BE CAREFUL NOT TO DAMAGE THE SLEEVE RIM.

• Slide the stem from the wheel holder

sleeve together with the sealing ring
(1), the cap (2), the upper bushing on
the fork leg (3), the lower bushing (4)
on the pipe.
NOTE
WHEN REMOVING THE STEM FROM THE WHEEL HOLD-
ER SLEEVE SOME PARTS MAY REMAIN INSIDE THE
SLEEVE. IF THIS OCCURS, THESE PARTS MUST BE RE-
MOVED AFTERWARDS, BEING CAREFUL NOT TO DAM-
AGE THE SLEEVE RIM AND THE UPPER BUSHING SEAT

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 BELLAGIO Suspensions

• Slide off the pumping member unit

from the holding tube.

• Remove the bottom buffer; this could

remain fitted on the wheel holder fork
leg; in this case remove it from inside.

• With the fingers, push the bottom valve

inside the shock absorber sleeve.

• Using a screwdriver, remove the snap

ring.

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• With the shock absorber rod outside

the sleeve, push the bottom valve.

• Check the bottom valve and its O-Ring,

replace them if they are damaged.

• Slide off the shock absorber rod to-

gether with the pumping member unit
from the sleeve after unscrewing the
lock nut on the rod end.
• Unscrew the nut (6) fixing the adjust-
ment unit and slide off all the compo-
nents. Carry out the appropriate
checks and/or replacements, and refit
according to order:

- cap (7);
- reed valve (8);
- cap (9);
- piston (10);
- fixing nut (6).

DURING SEALING UNIT REMOVAL, TAKE NOTE OF THE

EXACT POSITION OF THE REEDS (8)

HOLDING THE SHOCK ABSORBER ROD IN A VICE WITH-

OUT ANY SUPPORTS, IT IS POSSIBLE TO CRUSH IT
SINCE IT IS HOLLOW.

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The removal procedure is similar to that of shock

absorber "COMPRESSION" but the components
of the pumping member unit fixed to the shock ab-
sorber rod are different:
- pos. 11, counter spring;
- pos. 12, piston;
- pos. 13, ring for piston;
- pos. 14, right pin;
- pos. 15, calibration tabs;
- pos. 16, fixing nut.

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 the spring is in good conditions.

Check that the following components are in good conditions:

• upper bushing;
• lower bushing;
• 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:

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 Suspensions BELLAGIO

• seal ring;

• dust gaiter;

• O-Ring on the cap.

Filling oil

• Place the sleeve upright in a vice fitted

with protection jaws.
• 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
Adjustable telescopic fork oil (per fork leg)
0.485 l (0.128 US gal)
Oil level (from sleeve rim, without the spring
and with stem at the end of the stroke)

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150 mm (5.9 in)

• Introduce the spring and the preload

tube.

• Place the open washer locking the pre-

loading tube and the spring.

• Screw the lock nut on the pumping

member rod. So as to compress the
spring.

• Fix the fork upper cap to the pumping

member rod.
• Place the upper cap on the holding
tube being careful not to damage the
OR.
• Screw the upper cap to the prescribed
torque.

Steering bearing

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Adjusting play

• Operating from both sides, remove the

screw fixing the fork stems to the upper
plate.

• Loosen the upper plate back screw.

• Remove the chrome-plated cap.

• Unscrew and remove the head fixing

nut.

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• Unscrew and remove the two screws

fixing the light support to the steering
upper plate.

• Undo and remove the two handlebar

fixing screws.

• Collect the two chrome-plate washers.

• Slide off the fork upper plate moving it towards the instrument panel.

• Screw the ring nut to the prescribed

torque.

Locking torques (N*m)

Headstock ring nut - M25x1 (1) 7 Nm (5.16 lbf ft) -
the headstock should turn freely

Rear

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Removing the rear wheel

• Remove the exhaust terminals.

• Slide off the rear calliper from the disc.
• Lift the rear part of the vehicle with a belt and a hoist.

• Engage the first gear.

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

Shock absorbers

Removing

• Remove the exhaust terminals.

• Unscrew and remove the single con-
necting rod fixing bolt.

• Operating from the right side, unscrew

and remove the shock absorber lower
screw.

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• Place a shim washer between the

chassis and the rear wheel.
• Operating from the right side, unscrew
and remove the shock absorber upper
screw.
• Turn and remove the shock absorber
from the left side of the vehicle.

See also
Removing the tail pipe

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 INDEX OF TOPICS

CHASSIS CHAS

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 BELLAGIO Chassis

Swinging arm

Removing

• Remove the rear wheel.

• Unscrew and remove the two screws.
• Remove the speed sensor from the
fork.

• Unscrew and remove the fixing nut of

the connecting rod assembly and col-
lect the screw.

• Undo and remove the two screws.

• Remove the rider left footrest protec-
tion.

• Unscrew and remove the nut fixing the

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

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 Chassis BELLAGIO

• Remove the clamp from the dust guard

cap.

• Loosen the two swingarm terminal

screws.

• 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.

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 BELLAGIO Chassis

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.

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.

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 Chassis BELLAGIO

• 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.

• Place the rider left footrest protection.

• Tighten the two screws.

• Fit the dust guard cap in the gearbox.

• Lock the dust guard cap with a new
clamp.

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• 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.

• Place the dust-protection ring between

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

• Place the speed sensor on the fork and

screw the two screws.
• Fit the rear wheel.
• Place the rear brake calliper on the disc
and the brake pipe on the fork.

Bevel gears

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 Chassis BELLAGIO

Removing

• Remove the rear wheel.

• Unscrew and remove the two screws.
• Remove the speed sensor from the
fork.

• Unscrew and remove the nut fixing the

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

• Undo and remove the four screws.

• Remove the transmission casing slid-

ing off the universal joint.

Checking
Support unit

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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.

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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.

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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).

Pinion unit

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

Unscrew the ring nut (2) with the special spanner

(s4).

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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).

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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.

Wheel axle unit

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 Chassis BELLAGIO

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).

Assemble the bearings to the wheel axle.

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Turn the unit over.

Assemble the bearings to the wheel axle.

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.

Heat the casing.

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Insert the support group in the casing.

Assemble the cap and the ring.

Fit the cap on the support.

Fit the clamp.

Screw the clamp with the specific pliers.

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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.

Fit the casing.

Remove the two dowel pins.

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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.

Fit the cap with the washer.

Screw the cap to the prescribed torque.

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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.

Fit the cap in its seat.

Casing unit removal

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 Chassis BELLAGIO

Casing unit removal

Remove the cover (20).
Remove the plug (3) to drain out the oil.

Lift the cap (10).

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Remove the clamps (9) and (11).

Remove the cap (14).

Remove the screws (16).

Collect the ring (15).

Remove the screws (7).

Remove the casing (4).

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Remove the clamp (12).

Remove the cap (14).

Collect the ring (13).

Remove the support unit (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

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Possible Cause Operation

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

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.

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• Place the dust-protection ring between

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

• Place the speed sensor on the fork and

screw the two screws.
• Fit the rear wheel.
• Place the rear brake calliper on the disc
and the brake pipe on the fork.

Exhaust

Removing the tail pipe

• Loosen the fixing clamps.

• Undo and remove the internal screw

collecting the two washers.

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• Undo and remove the external screw

collecting the nut and the washer.

Removing the exhaust manifold

OPERATIONS VALID FOR BOTH MANIFOLDS

• Loosen the fixing clamps.

• Unscrew and remove the nuts from the

head stud bolts.

• Remove the exhaust manifolds.

• Disconnect the lambda sensor con-

nector.

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• Cut the clamp.

• Slide off the manifold - terminal cou-

pling mounting brackets from the vibra-
tion-damping rubber rings.

• Remove the manifold - terminal cou-

pling.

CHAS - 200

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 INDEX OF TOPICS

BRAKING SYSTEM BRAK SYS

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 Braking system BELLAGIO

Removal
OPERATIONS VALID FOR BOTH CALLIPERS

• Undo and remove the two screws and

collect the spacers.

• Remove the front brake calliper.

Front brake pads

Removal

• Remove the front brake calliper.

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• Remove the split pin.

• Slide off the pin.

• 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.

Rear brake pads

Removal

• Remove the rear brake calliper.

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 Braking system BELLAGIO

• Remove the lock.

• Remove the pin.

• 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 - 204

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 INDEX OF TOPICS

BODYWORK BODYW

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 Bodywork BELLAGIO

Air box

• Remove the air filter.

• Undo and remove the three lower
screws from the bracket.

• Slide off the oil vapour recovery pipe

from the blow-by tank.

• Loosen the clamps on the throttle bod-

ies and slide off the manifolds.

• Slide off the filter casing breather pipe.

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 BELLAGIO Bodywork

• Lift the filter casing slightly.

• Operating inside the filter slightly, un-
screw and remove the oil vapour re-
covery joint.
• Collect the gasket.
• Remove the filter casing by lifting it.

See also

Air filter

Fuel tank

• Unscrew and remove the rear screw.

• Disconnect the fuel pipe.

• Lift the fuel tank partially.

• Disconnect the two connectors.

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• Slide off the fuel breather pipe.

• Remove the fuel tank.

Battery
REMOVAL

• Remove the saddle.

• Disconnect the connector.

• Slide off the fuse boxes.

• Undo and remove the two screws.

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• Disconnect the elastic and remove the

battery cover.

• Undo and remove the screws fixing the

terminals.

• Remove the battery.

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 INDEX OF TOPICS

PRE-DELIVERY PRE DE

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 BELLAGIO Pre-delivery

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)

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 Pre-delivery BELLAGIO

- 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

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 BELLAGIO Pre-delivery

- 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.

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 A
Air filter: 32, 207
Air temperature sensor: 56, 68
Alternator:

B
Battery: 45, 49, 208
Brake: 202, 203
Brake pads: 202, 203

C
Chain: 121, 124–126
Clutch: 66, 98, 101–103, 106, 108, 109
Coil: 62
Connectors: 70
Crankcase: 19, 139
Crankshaft: 19, 139, 141, 143
Cylinder: 18, 112, 114, 117, 133–137, 141

D
Desmodromic drum: 100
Display: 157

E
ECU: 70
Electrical system: 12, 38, 39, 211
Engine oil: 29
Engine temperature sensor: 54
Exhaust: 198, 199
Exhaust manifold: 199

F
Fairings:
Fork: 160, 163, 165
Forks: 100
Front wheel: 160
Fuel: 33, 62, 207
Fuel pump: 62
Fuses: 47

G
Gearbox oil: 31

H
Handlebar:
Head cover: 111, 115, 139

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 I
Identification: 10
Instrument panel: 68

M
Maintenance: 8, 27

O
Oil pressure sensor: 64
Oil sump: 145

P
Primary shaft: 94, 99, 101

R
Rear wheel: 174
Recommended products: 20
Run/Stop switch: 69

S
Secondary shaft: 96, 100, 101
Shock absorbers: 174
Side stand: 67
Side stand sensor: 67
Speed sensor: 50
Stand: 67
Start-up: 46
Starter motor: 89, 105

T
Tank: 33, 207
Throttle body: 148
Transmission: 12, 28
Tyres: 14

V
Voltage regulator: 46

W
Wiring diagram: 40

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