MOTO GUZZI Engine V1100 Workshop Manual Download Page 84

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GEARBOX

4 - 5

Engine V1100

4.1.2.

OPENING THE GEARBOX

•

Remove the starter motor, see REMOVING THE
STARTER MOTOR.

•

Make sure that the gearbox is in neutral.

•

Loosen and remove the screw and remove the gear
shift lever.

•

Loosen and remove the plug.

•

Place a suitably sized container under it, unscrew and
remove the plug; drain all oil from the gearbox, as
described in the reference chassis manual, see
REFERENCE MANUALS.

•

Loosen and remove the three screws.

Summary of Contents for Engine V1100

Page 1: ...workshopmanual 00 2005 10 Engine V1100 UK Cod USA Cod 8140899...

Page 2: ...INTRODUCTION 0 1 Engine V1100 INTRODUCTION 0...

Page 3: ...INTRODUCTION 0 2 Engine V1100 TABLE OF CONTENTS 0 1 INTRODUCTION 3 0 1 1 FOREWORD 3 0 1 2 REFERENCE MANUALS 4 0 1 3 ABBREVIATIONS SYMBOLS CONVENTIONS 5...

Page 4: ...ed with the product The main technical modifications and changes in repair procedures are communicated to all Moto Guzzi dealers and agencies worldwide Such modifications will be included in subsequen...

Page 5: ...UALS guzzi part description 05 90 00 30 05 90 00 31 CHASSIS WORKSHOP MANUAL guzzi part description 8140856 8140857 8140858 8140859 8140860 8140861 8CM0077 8CM0078 ENGINE WORKSHOP MANUAL guzzi part des...

Page 6: ...utions per minute HC unburnt hydrocarbons ISC Idle Speed Control ISO International Standardization OrganisationOrganization kg kilograms kgm kilogram meter 1 kgm 10 Nm km kilometers km h kilometers pe...

Page 7: ...0 6 Engine V1100 TEST diagnostic check T B E I crown head Allen screw T C E I cheese head Allen screw T E hexagonal head T P flat head screw TSI Twin Spark Ignition UPSIDE DOWN inverted fork V volt W...

Page 8: ...GENERAL INFORMATION 1 1 Engine V1100 GENERAL INFORMATION 1...

Page 9: ...MANUAL 3 1 1 1 CONVENTIONS USED IN THE MANUAL 3 1 1 2 SAFETY WARNINGS 4 1 2 GENERAL RULES 5 1 2 1 BASIC SAFETY RULES 5 1 3 DANGEROUS ELEMENTS 8 1 3 1 WARNINGS 8 1 4 RUNNING IN 11 1 4 1 RUNNING IN 11 1...

Page 10: ...ight are referred to the motorcycle when viewed from the riding position Motorcycle operation and basic maintenance are covered in the OWNER S MANUAL In this manual any variants are identified with th...

Page 11: ...otential risk of personal injury Disregarding the instructions identified by this symbol may compromise the safety of the user the motorcycle and third parties DANGER Indicates a potential hazard whic...

Page 12: ...KEEP AWAY FROM CHILDREN HOT COMPONENT PARTS The engine and exhaust component parts become hot when the engine is running and will stay hot for some time after the engine has been stopped Wear insulati...

Page 13: ...r exhaust system which may still be hot to the touch to avoid scalds or burns Never put mechanical parts or other vehicle components in your mouth when you have both hands busy None of the motorcycle...

Page 14: ...ore assembly Apply a thin layer of lithium grease along the edges of oil seals Fit oil seals and bearings with the marking or serial number facing outwards in view ELECTRICAL CONNECTORS Disconnect ele...

Page 15: ...safety of the motorcycle Failure to maintain the lubricant level or the use of incorrect old or dirty lubricant can cause the engine or transmission to seize resulting in accident serious injury or de...

Page 16: ...alist or seek medical attention DO NOT DISPOSE OF BRAKE FLUID IN THE ENVIRONMENT KEEP AWAY FROM CHILDREN Avoid spillage Brake fluid can damage plastic or painted parts DANGER Do not use brake fluids o...

Page 17: ...er treatment product on the tires In particular do not allow the tire to come in contact with liquid fuel which rapidly deteriorates the tire rubber In case of contact with oil or fuel do not clean bu...

Page 18: ...he engine is running at low speed both during and after the running in period Until you have covered the first 100 km 62 mi use the brakes gently and avoid harsh prolonged braking This will help the b...

Page 19: ...BERS These numbers are necessary for vehicle registration NOTE Altering the vehicle s identification numbers is punishable by law with heavy fines and penalties Altering the frame number voids the war...

Page 20: ...TECHNICAL INFORMATION 2 1 Engine V1100 TECHNICAL INFORMATION 2...

Page 21: ...TECHNICAL INFORMATION 2 2 Engine V1100 TABLE OF CONTENT 2 1 TECHNICAL INFORMATION 3 2 1 1 TECHNICAL DATA 3 2 1 2 LUBRICANT TABLE 4 2 1 3 TIGHTENING TORQUES 5 2 1 4 SPECIAL TOOLS 7...

Page 22: ...cm 3 30 5 in 3 Transmission fluid 380 cm3 23 2 in3 TIMING SYSTEM Timing diagram 2 valves with rods and rocker arms Values with inspection clearance between rocker arms and valve intake 0 10 mm 0 0039...

Page 23: ...ssion fluid RECOMMENDED TRUCK GEAR 80 W 90 Gearbox fluid RECOMMENDED ROTRA MP S 85 W 90 Bearings and other lubrication points RECOMMENDED BIMOL GREASE 481 AUTOGREASE MP or GREASE SM2 As an alternative...

Page 24: ...1 M18 150 belt tension 50 LOCKS stud bolt M10x35 2 M10 40 Linkage 1 42 nut EA ZB M10x1 5 2 M10 40 42 head bolt 1 40 42 stud bolt M8x75 2 M8 35 stud bolt M8x66 1 M8 35 Hex head screw DA M8x25 2 M8 25 F...

Page 25: ...10x60 1 M10 see nut nut M10x1 5 flanged 1 M10 30 TBEI screw DA M8x50 1 M8 nut EBFM DA MF16x1 5 1 M16 80 spark plug NGK BPR 6ES 2 20 30 spark plug PMR8b 2 13 15 TCEI screw M6x16 4 M6 8 12 FUEL FEED CON...

Page 26: ...essary for correctly removing refitting and adjusting Unsuitable tools and or improvised procedures could cause damage that might be avoided if the special tools are used Following are the special too...

Page 27: ...92 96 00 10 Index for checking timing 17 94 75 60 11 Tool for removing flange on flywheel side 12 91 36 00 12 Tool for locking flywheel and starter gear 12 91 18 01 13 Tool for removing and installin...

Page 28: ...ENGINE 3 1 Engine V1100 ENGINE 3...

Page 29: ...TIMING 19 3 3 4 MEASURING THE SENSOR GAP 21 3 4 OIL PUMP 23 3 4 1 REMOVING THE OIL PUMP 23 3 5 HEADS 24 3 5 1 REMOVING THE HEAD COVERS 24 3 5 2 REMOVING THE HEADS 25 3 5 3 CHECKING THE COMPONENTS 30 3...

Page 30: ...ENGINE 3 3 Engine V1100 3 1 REMOVING THE ACCESSORIES 3 1 1 REMOVING THE STARTER MOTOR Loosen and remove the two screws and set aside the washers Slide out the starter motor...

Page 31: ...3 1 2 REMOVING THE BLOW BY SYSTEM Loosen the oil recovery line fitting and remove the oil recovery line from the crankcase Remove the tie Loosen the two clamps securing the oil breather line Remove th...

Page 32: ...ENGINE 3 5 Engine V1100 Loosen and remove the oil recovery line positioning screw Release the oil recovery line Remove the complete blow by system...

Page 33: ...ENGINE 3 6 Engine V1100 3 2 GENERATOR 3 2 1 REMOVING THE GENERATOR Loosen and remove the six screws and set aside the bushings Remove the cover Loosen and remove the eight screws...

Page 34: ...ENGINE 3 7 Engine V1100 Loosen and remove the two screws Loosen the nut and set aside the screw Loosen the screw Loosen the nut and release the adjuster so that the generator is free to slide down...

Page 35: ...Completely loosen and remove the screw Remove the belt and the generator complete with pulley Using an air gun loosen and remove the nut and set aside the spacer Slide out the lower pulley Loosen and...

Page 36: ...ENGINE 3 9 Engine V1100 Remove the generator subframe Remove the seal if necessary...

Page 37: ...al using the timing cover seal drift part no 05 92 72 30 Change the gasket and position the generator subframe using the front cover insertion cone part no 05 91 17 30 Remove the front cover insertion...

Page 38: ...0 Tighten the ten screws proceed in steps and in a cross pattern Position the lower pulley and the spacer Tighten the nut to the specified torque Position the generator and the timing belt Position th...

Page 39: ...ition the screw and nut and tighten them Using the belt tensioning tool tension the belt to the specified value and tighten the adjuster Remove the belt tensioning tool Tighten the lock nut Tighten th...

Page 40: ...ENGINE 3 13 Engine V1100 Tighten the four screws proceed in steps and in a cross pattern Fit the timing cover Tighten the five screws proceed in steps and in a cross pattern...

Page 41: ...ual see REFERENCE MANUALS Remove the generator following the instructions given in REMOVAL Remove both heads see REMOVING THE HEADS Mark the timing references to be restored upon reassembly Using the...

Page 42: ...and remove the central nut securing the timing drive gear on the crankshaft and set aside the washer Loosen and remove the nut and set aside the washer Slide out the chain tensioner and set aside the...

Page 43: ...3 16 Engine V1100 Slide out the pick up ring and set aside the dowel Loosen and remove the three screws and set aside the washers Slide out the flange Slide out the tappets from their seats on either...

Page 44: ...V1100 Slide out the camshaft REASSEMBLY NOTE To refit the timing system suitably heat the engine with a heater so as to correctly fit the camshaft while avoiding damage Follow the removal instruction...

Page 45: ...ide 47 000 46 984 1 85039 1 84976 47 025 47 050 1 85137 1 85236 Flywheel side 32 000 31 984 1 25984 1 25921 32 025 32 050 1 26082 1 26181 0 025 0 066 0 00098 0 00260 TAPPET TO SEAT ON CRANKCASE COUPLI...

Page 46: ...threaded hole to the left of the crankcase using a screw Fit a dial gauge support in the left cylinder external spark plug hole and fit a dial gauge on the support Turn the crankshaft until the left...

Page 47: ...se using a screw Turn the degree wheel clockwise until reference D matches the reference at the center of the gearbox inspection hole valves closed Repeat the procedure described previously for the le...

Page 48: ...0 3 3 4 MEASURING THE SENSOR GAP Loosen and remove the two screws and remove the sensor Fit a flat washer on the sensor and measure its thickness Position the sensor on the timing cover and place it a...

Page 49: ...e and cover using a feeler gauge Subtract the flat washer thickness from this value to determine the gap between the sensor and the pick up ring Remove the washer smear the plate with suitable sealant...

Page 50: ...PUMP 3 4 1 REMOVING THE OIL PUMP Drain all engine oil Remove the generator see REMOVING THE GENERATOR Remove the timing system see REMOVING THE TIMING SYSTEM Loosen and remove the four oil pump securi...

Page 51: ...dure applies to both head covers Loosen and remove the eight screws and set aside the bushings Remove the head cover and set aside the gasket NOTE Repeat the same procedure described above in reverse...

Page 52: ...e is valid for both cylinder heads Remove the head cover see REMOVING THE HEAD COVERS Unscrew and remove the external spark plug Turn the crankshaft to set the left cylinder to TDC in combustion stage...

Page 53: ...V1100 Remove the rocker arm and set aside the three washers Loosen the nut and disconnect the line delivering oil to the head Loosen and remove the threaded plug Loosen and remove the socket nut and s...

Page 54: ...Loosen and remove the four nuts and set aside the relevant washers Remove the rocker arm support Slide out the two rocker arm rods Using the suitable special tool part no 05 90 19 30 loosen and remove...

Page 55: ...NGINE 3 28 Engine V1100 Loosen and remove the two screws and set aside the two washers Slightly detach the head from the cylinder and remove the four O rings Slide out the head and set aside the gaske...

Page 56: ...on top retainer with a mallet so as to detach the two valve cotters 1 from top plate 2 Once the two valve cotters 1 are detached screw in until they can be removed from their seats on the valves loos...

Page 57: ...d by changing the valves only To fit the valve guides to the head proceed as follows Heat up the head in an oven at about 60 C 140 F Lubricate the valve guides Fit the circlips Press the valve guides...

Page 58: ...ATS Grind the valve seats with a cutter Seat slant angle is 45 5 After milling grind to ensure correct coupling and perfect sealing between the valve head and the ring nut INTAKE VALVE SEAT DETAIL VIE...

Page 59: ...ner 5 and the shims Refit the external spring 4 Refit the internal spring 3 Fit the top retainer 2 Position the two valve cotters 1 in their seats on the valves Compress the spring with the suitable t...

Page 60: ...ENGINE 3 33 Engine V1100 Fit the two washers and tighten the two screws Using the suitable special tool part no 05 90 19 30 tighten the internal spark plug Install the two rocker arm rods...

Page 61: ...NGINE 3 34 Engine V1100 Install the rocker arm support and change the four O rings Fit the four washers and tighten the four nuts Install the washer and tighten the socket nut Tighten the threaded plu...

Page 62: ...ine delivering oil to the head and tighten the nut Fit the six washers and install the rocker arms Install the rocker arm shafts Turn the crankshaft to set the left cylinder to TDC in combustion stage...

Page 63: ...ENGINE 3 36 Engine V1100 Install the external spark plug Change the gasket and install the head cover see REMOVING THE HEAD COVERS...

Page 64: ...LATION NOTE The following procedure applies to both cylinder heads REMOVAL Remove the head see REMOVING THE HEADS Slide out the gasket Remove the cylinder clear of the stud bolts do not damage the pis...

Page 65: ...000 92 006 3 62204 3 62227 92 006 92 012 3 62227 3 62250 92 012 92 018 3 62250 3 62275 CLASS SELECTION FOR PISTON UP TO ENGINE NO KR014485 mm in CLASS A CLASS B CLASS C 91 954 91 960 3 62022 3 62046...

Page 66: ...fference in weight is allowed up to 1 5 grams 0 0033 lb Check the piston rings and oil scraper ring Every piston fits 1 top ring 1 intermediate ring 1 oil scraper ring Piston ring end gaps must be off...

Page 67: ...ons to cylinders of different classes Fit the gudgeon pin Fit the gudgeon pin circlip Remove the rag used to avoid that foreign matter enters the crankcase Turn the piston rings so that the end gaps a...

Page 68: ...ENGINE 3 41 Engine V1100 Remove the piston ring tool part no 05 92 80 30 and position the cylinder Fit the gasket at the cylinder base Install the head see REFITTING THE HEADS...

Page 69: ...HE CLUTCH Fit the locking tool part no 12 91 18 01 to the flywheel and loosen the six flywheel screws work in a cross pattern and in steps Remove the flywheel CHECK Make sure that the flywheel mating...

Page 70: ...ngine V1100 REASSEMBLY Perform the removal procedure in reversed order NOTE Respect flywheel position reference marks WARNING Replace the screws upon reassembly as they are subject to considerable str...

Page 71: ...CLUTCH Remove the flywheel see REMOVAL CHECK AND REASSEMBLY Remove the timing system see REMOVING AND REFITTING Remove the oil sump see REMOVAL CHECK AND REASSEMBLY From inside the crankcase loosen t...

Page 72: ...ENGINE 3 45 Engine V1100 Using the suitable special tool part no 12 91 36 00 remove the crankshaft flange Remove the seal if necessary Slide the crankshaft from the back...

Page 73: ...alloy to prevent settling replace them in case of jamming or wear marks When changing the bearings it might be necessary to grind the crank pin Before grinding the crank pin we recommend to measure it...

Page 74: ...weight selection class 642 2 5 1 4153 0 0055 476 3 5 1 0494 0 0077 White 647 2 5 1 4263 0 0055 479 5 3 5 1 0571 0 0077 Light blue 652 2 5 1 4374 0 0055 165 1 0 3638 0 0022 483 3 5 1 0648 0 0077 Orange...

Page 75: ...n 3 0 3 2 mm 0 118 1 260 in for the journal on flywheel side 1 5 1 8 mm 0 059 0 071 in for the journal on timing side CHECKING THE WEIGHT FOR CRANKSHAFT BALANCING The connecting rods with bolts fitted...

Page 76: ...crankshaft shims is 0 30 mm 0 01181 in 0 50 mm 0 01968 in Tighten the bolts on the caps with a torque wrench to the specified tightening torque CRANKSHAFT Correctly set the crankshaft support flanges...

Page 77: ...ary to place a suitable container under the sump to collect used oil and drain all oil from the sump If necessary remove the filter with the suitable special tool part no 01 92 91 00 Loosen and remove...

Page 78: ...Loosen and remove the four screws and remove the black oil sump Loosen and remove the two screws Loosen and remove the two screws Remove the mesh filter and set aside the gasket Remove the black flang...

Page 79: ...ss the oil pressure control valve and the thermostatic valve Remove them if necessary CHECK Check that the mesh filter is not dirty wash and blow with compressed air if necessary REASSEMBLY On assembl...

Page 80: ...GEARBOX 4 1 Engine V1100 GEARBOX 4...

Page 81: ...ING THE GEARBOX 5 4 1 3 DISASSEMBLING THE PRIMARY SHAFT 12 4 1 4 DISASSEMBLING THE SECONDARY SHAFT 14 4 1 5 DISASSEMBLING THE CLUTCH SHAFT 17 4 1 6 CHECK 18 4 1 7 REASSEMBLY 20 4 2 CLUTCH 21 4 2 1 REM...

Page 82: ...GEARBOX 4 3 Engine V1100 4 1 GEARBOX 4 1 1 DIAGRAM...

Page 83: ...ket 30 Seal 31 Bushing 32 Gasket 33 Oil drain plug 34 Roller bearing 35 Circlip 36 Belleville washer 37 Spring pusher 38 Shaped washer 39 Sleeve 40 Circlip 41 Idle gear 42 Ball bearing 43 Gear 44 Gear...

Page 84: ...at the gearbox is in neutral Loosen and remove the screw and remove the gear shift lever Loosen and remove the plug Place a suitably sized container under it unscrew and remove the plug drain all oil...

Page 85: ...GEARBOX 4 6 Engine V1100 Loosen and remove the two screws Loosen and remove the screw Remove the gearbox Place the gearbox on the suitable gearbox support part no 14 92 96 00 and in a vice...

Page 86: ...odometer fitting and set aside the stop washer that stays inside the gearbox Slide out the cylinder and set aside the O ring and the washer Remove the thrust bearing and cap Slide out the two bushing...

Page 87: ...e washer ends Using the suitable pin wrench part no 05 91 26 30 and clutch locking tool part no 30 91 28 10 loosen and remove the ring nut set aside the inner clutch body Using the suitable tool part...

Page 88: ...he gearbox see OPENING THE GEARBOX Release the spring Press on the selector to help remove the complete transmission lever Loosen and remove the reference threaded pin Use elastic bands to tie the gea...

Page 89: ...the bearings from the gearbox Place the gearbox shafts on a bench and remove the elastic bands paying attention not to damage the unit Separate the shafts and mark the forks before removal Slide out t...

Page 90: ...GEARBOX 4 11 Engine V1100 If necessary replace the bearings and remove the clutch shaft...

Page 91: ...E PRIMARY SHAFT Open the gearbox see OPENING THE GEARBOX Work on the primary shaft from the side of the second speed gear Remove the second speed gear set aside the roller cage Remove the sixth speed...

Page 92: ...Remove the third and fourth speed gear Remove the circlip and set aside the washer Remove the fifth speed gear and set aside the roller cage Using a suitable heater heat up the shaft and remove the t...

Page 93: ...SASSEMBLING THE SECONDARY SHAFT Open the gearbox see OPENING THE GEARBOX Work on the secondary shaft from the splined side Remove the washer Remove the second speed gear and set aside the roller cage...

Page 94: ...gine V1100 Remove the sixth speed gear Remove the circlip and set aside the washer Remove the fourth speed gear and set aside the roller cage Remove the third speed gear and set aside the roller cage...

Page 95: ...GEARBOX 4 16 Engine V1100 Remove the circlip Remove the fifth speed gear Remove the circlip the washer and slide out the first speed gear set aside the roller cage If necessary remove the bearing...

Page 96: ...d bearing 2 set aside the O ring 3 Working on the gearbox side remove the circlip 13 and the two split rings 12 set aside the roller bearing 14 Remove the retainer 11 Carefully remove the Belleville w...

Page 97: ...ar Replace the fork if necessary Check fork movement replace the forks if movement is irregular CHECKING THE DESMODROMIC UNIT Check the gear change drum for damage scratches and wear marks and replace...

Page 98: ...a gauge and a centering unit measure secondary shaft runout and replace it if it does not comply with the specifications Secondary shaft limit runout 0 08 mm 0 0031 in Check the transmission gears fo...

Page 99: ...EMBLY NOTE To reassemble the clutch shaft the secondary shaft and the primary shaft and to close the gearbox follow the removal instructions in reverse order Remember to replace all the seals circlips...

Page 100: ...LUTCH Remove the gearbox unit see REMOVING THE GEARBOX Fit the locking tool part no 12 91 18 01 and tool part no 30 90 65 10 to compress clutch springs on the flywheel Loosen and remove the eight scre...

Page 101: ...GEARBOX 4 22 Engine V1100 From inside the flywheel remove the clutch plate the intermediate plate the second clutch plate the pusher plate nut...

Page 102: ...GEARBOX 4 23 Engine V1100 the pusher plate together with springs...

Page 103: ...h the driven plate is perfectly flat Check that the toothing inside the flywheel is in good condition Driven plates Check that the surfaces mating with the driven plates are perfectly smooth and flat...

Page 104: ...n the flywheel as follows the spring pusher plate together with springs Ensure that the reference mark on the pusher plate tooth matches the flywheel reference mark Fit the locking tool part no 12 91...

Page 105: ...GEARBOX 4 26 Engine V1100 Remove the locking tool part no 12 91 18 01 Fit the clutch plate Fit the intermediate metal plate Fit the clutch plate...

Page 106: ...the reference mark to the flywheel one Tighten the eight screws securing the gear wheel to the flywheel to the specified torque proceed in a cross pattern Remove tool part no 30 90 65 10 compressing...

Page 107: ...GEARBOX 4 28 Engine V1100...

Page 108: ...Moto Guzzi S p a Via E V Parodi 57 23826 Mandello del Lario LECCO Italy Tel 39 0341 709111 Fax 39 0341 709220 www motoguzzi it www servicemotoguzzi com...

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