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Trouble travels in packs - Norge gearbox(?) clunk, clutch adjustment and error code

bobra

Cruisin' Guzzisti
Joined
Oct 28, 2008
Messages
104
Location
Adelaide, S. Australia
Greeting all. It seems the Guzzi god has decided to give me an early Christmas headache and I'd be very grateful for some advice.

The story so far....

I dropped my 2007 Norge (well, it fell off its stand) and snapped the clutch lever. No big deal - replaced it. New clutch lever - everything seemed to be working OK. A 35km trip on the next day and the clutch is barely engaging. Let the bike cool down and it's ok until near home and it starts to slip again. So... I assumed the clutch was out of adjustment and I wound back the clutch activation pin.

While in the process, I started the bike on the centre stand to check when the clutch actually engaged. As soon as I engaged the clutch, a noise emanated from the gear box (maybe) that sounded like it was tearing itself apart. Clunk, clunk - not regular but it sounded a bit like the "clunk" you hear when you engage first gear.

Then I noticed the "SERVICE!" error on the dash. I've looked at at the diagnostics and the only thing I can see is dash error 02 - A is "o" and the M flashes between "o" and "x". The service manual says error 02 is "key not present or transponder not working" but the bike starts ok. I cannot removed this error message (I've even tried disconnecting and reconnecting the dash).

So - questions for the wise group are:

1. How do you know if the clutch is correctly adjusted? Trial and error or is there a critical spot where the adjustment pin should be?

2. What is the noise? I've read here on the forum that some sort of gearbox noise is "normal" when the bike is cold and it goes away after the bike has been ridden for a bit but I'm not keen to test this until I know for sure!

3. What does the error message actually mean and how do I clear it?

Many thanks in advance for your wisdom

Cheers

Rob
 
As for the noise while on the center stand and in gear, that is normal on an unloaded drive train. As to the clutch issue, it may be adjustment to allow the piston to retract and expose the return port in the master cylinder, but if it only slips when hot, check that the master cylinder is not over full and fluid can return when the clutch lever is not actuated. Also if the fluid hasn't been changed for some time, the return port may be partially blocked with crud.
 
Thanks John. That's comforting regarding the gearbox noise! Is there any way of checking if the clutch return port is blocked?

I Think I've misinterpreted the dash errors. the actual error map is:

A M
01 o x
02 o * [sometime "x" and sometimes flashing from "o" to "x"]
03 o x
04 o x
05 o x
06 o x
07 o o
08 o o

There were so many "x"s I thought they were normal :(

Can anyone help me interpret this? Firstly, what do the "A" and "M" stand for? According to the service manual, errors 1 through 6 are not all related - some related to the immobiliser while 5 is the fuel sensor and 6 is the air temperature sensor. They can't all have failed at the some time. Any attempt to clear them either has no effect or they instantly return (I can't tell which). Also, are these major errors that would initiate the "SERVICE" warning?

Many thanks

Rob
 
The "A" column is for Active, The "M" column is for Memory (has happened in the past but not active now). My guess is a bad connection at the antenna for the key around the ignition switch. I can be a bit trouble some to get to it. Cleaning the connections with a good contact cleaner may solve you issue.
 
Just to close the loop on this, in case someone else encountered the problem ... I eventually discovered that there are two more pages of error codes that you have to scroll through <doh!>. The ACTIVE error was ECU 56 - vehicle speed error. I assume that when testing the clutch with the bike on the stand, I activated the ABS and the computer sensed the wheels were not turning at the same speed. A quick trip around the block cleared the error so we are now back to normal.

Cheers

Rob
 
That's actually a good piece of info to know and consider :wondering:. Always nice to see all the details! Thx...
 
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