MOTO GUZZI V750 IE Service Station Manual Download Page 3 | Manualshive

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SERVICE STATION MANUAL

Engine V750 IE

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 motorcycles. 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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Summary of Contents for V750 IE

Page 1: ...SERVICE STATION MANUAL B043109 Engine V750 IE ...

Page 2: ... original spare parts undergo quality control procedures to guarantee reliability and durability The descriptions and images in this publication are given for illustrative purposes only and are not binding While the basic characteristics as described and illustrated in this booklet remain unchanged Piaggio C S p A reserves the right at any time and without being required to update this publication...

Page 3: ...s 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 upd...

Page 4: ......

Page 5: ...INDEX OF TOPICS CHARACTERISTICS CHAR SPECIAL TOOLS S TOOLS ENGINE ENG ...

Page 6: ...INDEX OF TOPICS CHARACTERISTICS CHAR ...

Page 7: ...Type Quantity Torque Notes 1 Column nuts 4 42 Nm 30 98 lbf ft 2 Nut M8x1 25 6 22 Nm 16 22 lbf ft 3 TCEI screw M6x25 12 10 Nm 7 37 lbf ft 4 Oil drainage plug M10x1 1 40 Nm 29 5 lbf ft Spark plugs 2 30 Nm 22 13 lbf ft Engine V750 IE Characteristics CHAR 7 ...

Page 8: ...os Description Type Quantity Torque Notes 1 TCEI screw M6x25 10 10 Nm 7 37 lbf ft 2 TCEI screw M6x30 2 10 Nm 7 37 lbf ft 3 Alternator cover screws M6x35 5 10 Nm 7 37 lbf ft Loctite 243 Characteristics Engine V750 IE CHAR 8 ...

Page 9: ... 4 Nuts tightening M10x1 5 4 42 Nm 30 98 lb ft 5 Column nut 4 25 Nm 18 44 lb ft 6 Nut 2 28 Nm 20 65 lb ft 7 Internal Head cover screws M6x25 4 8 10 Nm 5 90 7 37 lb ft 8 Outer head cover screws M6x52 5 8 8 10 Nm 5 90 7 37 lb ft CRANKSHAFT pos Description Type Quantity Torque Notes 1 Oil plug 1 15 Nm 11 06 lbf ft Loctite 601 2 Connecting rod screws 4 33 Nm 24 34 lbf ft 3 Flywheel screws 6 42 Nm 30 9...

Page 10: ...otes 1 Tone wheel screw M8x22 1 25 Nm 18 44 lb ft 2 Timing system gear screws 2 25 Nm 18 44 lb ft Loctite 243 3 Chain tensioner screw M6x16 1 10 Nm 7 38 lb ft 4 Valve clearance adjuster screw M6x1 4 10 Nm 7 38 lb ft Characteristics Engine V750 IE CHAR 10 ...

Page 11: ... pump screws M6x35 3 10 Nm 7 38 lbf ft Loctite 648 4 Oil filter screw 1 6 Nm 4 43 lbf ft CLUTCH I pos Description Type Quantity Torque Notes 1 Crown screws M6x16 6 10 Nm 7 38 lbf ft Loctite 243 2 Gearbox screws M8x35 5 25 Nm 18 44 lbf ft 3 Clutch belt cover screws M6x30 11 10 Nm 7 38 lbf ft Loctite 243 Engine V750 IE Characteristics CHAR 11 ...

Page 12: ...uantity Torque Notes 1 Clutch shaft nut 1 100 Nm 73 76 lbf ft Loctite 243 GEARBOX pos Description Type Quantity Torque Notes 1 Neutral sensor 1 8 Nm 5 90 lbf ft 2 Screws M6x14 4 10 Nm 7 38 lbf ft Characteristics Engine V750 IE CHAR 12 ...

Page 13: ... 7 38 lbf ft 4 Gearbox cover screws M6x35 2 10 Nm 7 38 lbf ft 5 Gearbox cover screws M8x35 4 22 Nm 16 23 lbf ft 6 Oil breather plug 1 20 Nm 14 75 lbf ft GEARBOX pos Description Type Quantity Torque Notes 1 Main shaft nuts 2 60 Nm 44 25 lbf ft Engine V750 IE Characteristics CHAR 13 ...

Page 14: ...x12 1 10 Nm 7 38 lbf ft Loctite 243 2 Screws M6x16 2 10 Nm 7 38 lbf ft ALTERNATOR REGULATOR pos Description Type Quantity Torque Notes 1 Alternator nut M16 1 90 Nm 66 38 lbf ft Loctite 243 2 Front cover fixing screws M5x65 3 6 Nm 4 43 lbf ft Characteristics Engine V750 IE CHAR 14 ...

Page 15: ...on Type Quantity Torque Notes 1 Starter motor fixing screws M8x35 2 25 Nm 18 44 lbf ft THROTTLE BODY pos Description Type Quantity Torque Notes 1 Pipe fixing screw M6x22 4 10 Nm 7 38 lbf ft Engine V750 IE Characteristics CHAR 15 ...

Page 16: ...INDEX OF TOPICS SPECIAL TOOLS S TOOLS ...

Page 17: ...72 20 Tool for fitting seal ring on timing system cover 10 90 72 00 Tool for valve removal and refitting 19 92 61 00 Punch for seal ring of bevel gear set pin ion 19 92 88 00 Bevel gear set alignment pre fitting tool 19 92 94 00 Punch for clutch shaft bearing on housing Engine V750 IE Special tools S TOOLS 17 ...

Page 18: ...aft 19 92 72 00 Punch for fitting seal ring on gearbox cov er secondary shaft 19 90 65 00 Tool for clutch plate fitting centring 19 91 18 00 Flywheel locking tool 19 92 72 02 Spacer for fitting ring on secondary shaft 19 90 70 00 Extractor for internal ring on drilled bolt Special tools Engine V750 IE S TOOLS 18 ...

Page 19: ...ssion gear locking tool for gear box removal 19 92 63 00 Punch for primary shaft bearing on gear box 19 92 64 00 Punch for external ring of tapered bearing on bevel gear set pinion holding body 19 92 65 00 Punch for external ring of gearcase bear ing 19 92 76 00 Extractor for swinging arm holder bearing on gearbox cover Engine V750 IE Special tools S TOOLS 19 ...

Page 20: ... to drilled pin 12 91 20 00 Tool to fit the flywheel side flange togeth er with sealing ring on the crankshaft 19 92 71 00 Tool to fit the seal ring on the flywheel side flange 19 90 71 60 Clutch shaft locking equipment 19 90 54 60 Clutch shaft nut locking tool 19 90 25 00 Gearbox support Special tools Engine V750 IE S TOOLS 20 ...

Page 21: ...2 60 20 Punch for cap installation on valve guide 19 92 73 20 Tool for fitting seal ring on camshaft tim ing system cover 19 92 64 60 Inserting tool for outer ring of secondary shaft bearing Engine V750 IE Special tools S TOOLS 21 ...

Page 22: ...INDEX OF TOPICS ENGINE ENG ...

Page 23: ...Gearbox Diagram GEARBOX pos Description Type Quantity Torque Notes 1 Main shaft nuts 2 60 Nm 44 25 lbf ft Engine V750 IE Engine ENG 23 ...

Page 24: ...lbf ft Loctite 243 2 Screws M6x16 2 10 Nm 7 38 lbf ft CLUTCH I pos Description Type Quantity Torque Notes 1 Crown screws M6x16 6 10 Nm 7 38 lbf ft Loctite 243 2 Gearbox screws M8x35 5 25 Nm 18 44 lbf ft 3 Clutch belt cover screws M6x30 11 10 Nm 7 38 lbf ft Loctite 243 Engine Engine V750 IE ENG 24 ...

Page 25: ...CLUTCH II pos Description Type Quantity Torque Notes 1 Clutch shaft nut 1 100 Nm 73 76 lbf ft Loctite 243 Gearbox Engine V750 IE Engine ENG 25 ...

Page 26: ... 3 Gearbox cover screws M6x30 5 10 Nm 7 38 lbf ft 4 Gearbox cover screws M6x35 2 10 Nm 7 38 lbf ft 5 Gearbox cover screws M8x35 4 22 Nm 16 23 lbf ft 6 Oil breather plug 1 20 Nm 14 75 lbf ft Removing the gearbox Remove the gearbox fixing screws from the engine Remove the gearbox Gearbox shafts Engine Engine V750 IE ENG 26 ...

Page 27: ...tch shaft onto the gearbox so that the gear becomes engaged with the primary shaft gear Install the specified locking tool onto the clutch shaft splines Unscrew the transmission gear retain ing nut and slide off the thrust washer Engine V750 IE Engine ENG 27 ...

Page 28: ... Remove the gear and the clutch shaft Unscrew the breather cap with its pawl Unscrew and remove the neutral indi cator Engine Engine V750 IE ENG 28 ...

Page 29: ... Unscrew the gearbox cover bolts and remove the cover tapping it with a mal let Slacken the lock nut and unscrew the pre selector positioning eccentric screw Engine V750 IE Engine ENG 29 ...

Page 30: ...he pre selector and remove the pre selector seal ring After unscrewing the retaining plate fixing screws remove the complete set of gears shafts and forks See also Removing the gearbox Engine Engine V750 IE ENG 30 ...

Page 31: ...utch shaft Remove the clutch bell Undo the three screws with washers and remove the bearing retaining plate Undo the clutch shaft fixing nut Slide off the clutch shaft and remove the seal ring Engine V750 IE Engine ENG 31 ...

Page 32: ...See also Clutch bell removal Assembling the clutch shaft Fit the clutch shaft using a plastic mal let and refit circlip and seal ring Engine Engine V750 IE ENG 32 ...

Page 33: ...Gear selector Reassembling the gear selector After refitting the complete shaft as sembly to the gearbox cover insert the spring and insert the two tangs onto the pre selector peg making sure that the two tangs are equally spaced both on the peg and at tang ends Engine V750 IE Engine ENG 33 ...

Page 34: ... Refit the eccentric screw to the cover together with its lock nut and make sure that the eccentric end of the screw is facing the selector nut Refit the selector spacer Engine Engine V750 IE ENG 34 ...

Page 35: ...ure that the two tangs of the spring lo cate into the adjuster screw groove then turn the screw by 90 and tighten the lock nut Refit the gasket and tighten the gear box cover fixing screws to the prescri bed torque Engine V750 IE Engine ENG 35 ...

Page 36: ... Insert the gear with its washer onto the gearbox primary shaft tighten the re taining nut to the prescribed torque and squash with a punch Engine Engine V750 IE ENG 36 ...

Page 37: ...lug 1 15 Nm 11 06 lbf ft Loctite 601 2 Connecting rod screws 4 33 Nm 24 34 lbf ft 3 Flywheel screws 6 42 Nm 30 98 lbf ft Loctite 243 Removing the flywheel Remove the gearbox Remove the retainer ring and the clutch engagement disengagement cap Engine V750 IE Engine ENG 37 ...

Page 38: ...ywheel to the crankshaft and then remove it 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 Engine Engine V750 IE ENG 38 ...

Page 39: ...ighten the screws and fit the specified flywheel locking tool Specific tooling 19 91 18 00 Flywheel locking tool Tighten the screws following a criss cross pattern with a torque wrench set to the prescribed torque It is advisable to change the fixing screws securing flywheel to crankshaft Insert the clutch engagement disen gagement cap with its retainer ring Engine V750 IE Engine ENG 39 ...

Page 40: ...EM COVER pos Description Type Quantity Torque Notes 1 TCEI screw M6x25 10 10 Nm 7 37 lbf ft 2 TCEI screw M6x30 2 10 Nm 7 37 lbf ft 3 Alternator cover screws M6x35 5 10 Nm 7 37 lbf ft Loctite 243 Engine Engine V750 IE ENG 40 ...

Page 41: ...ty Torque Notes 1 Alternator nut M16 1 90 Nm 66 38 lbf ft Loctite 243 2 Front cover fixing screws M5x65 3 6 Nm 4 43 lbf ft Removing the generator Unscrew the fixing screws and remove the alternator unit protection covers Engine V750 IE Engine ENG 41 ...

Page 42: ...screws fixing the stator to the timing system cover and slide off the stator Unscrew the nut fixing the rotor to the crankshaft slide off the rotor remove the key and collect the washer Engine Engine V750 IE ENG 42 ...

Page 43: ...alling the generator Insert supporting washer key and ro tor and tighten the nut to the prescri bed torque with a torque wrench Fit stator and cover and tighten the three screws Engine V750 IE Engine ENG 43 ...

Page 44: ... Fit stator cover Tighten the five cover fixing screws to the prescribed torque Revolution sensor Undo and remove the two screws and remove the sensor Engine Engine V750 IE ENG 44 ...

Page 45: ...e timing system cover and tighten the two fastening screws to the prescribed torque Starter motor STARTER MOTOR pos Description Type Quantity Torque Notes 1 Starter motor fixing screws M8x35 2 25 Nm 18 44 lbf ft Engine V750 IE Engine ENG 45 ...

Page 46: ...Removing the starter motor Remove the starter motor fixing screws Slide off the starter motor Clutch side Engine Engine V750 IE ENG 46 ...

Page 47: ...23 lbf ft 6 Oil breather plug 1 20 Nm 14 75 lbf ft CLUTCH I pos Description Type Quantity Torque Notes 1 Crown screws M6x16 6 10 Nm 7 38 lbf ft Loctite 243 2 Gearbox screws M8x35 5 25 Nm 18 44 lbf ft 3 Clutch belt cover screws M6x30 11 10 Nm 7 38 lbf ft Loctite 243 Clutch bell removal Secure gearbox clutch bell to the sup port clamped in a vice fit the nut lock ing tool and turn the shaft using th...

Page 48: ... Loosen the Allen screws that secure the clutch bell to the gearbox Detach and remove the clutch bell to gether with the clutch shaft tapping lightly around clutch bell edge Engine Engine V750 IE ENG 48 ...

Page 49: ...over Fit the specified flywheel locking tool on the crankcase Specific tooling 19 91 18 00 Flywheel locking tool Unscrew the clutch plate fixing screws and remove clutch plate together with starting sprocket See also Clutch bell removal Engine V750 IE Engine ENG 49 ...

Page 50: ...ngs and make sure that clutch plate thickness is not lower than the specified value if so replace the clutch plate Starting sprocket Check that the supporting surface with the driven plate is perfectly smooth and even Also check that the toothing where the starter mo tor pinion works is not chipped or scratched oth erwise replace it Engine Engine V750 IE ENG 50 ...

Page 51: ...tooling 19 91 18 00 Flywheel locking tool Insert the cap with its seal ring Position the specified clutch plate cen tring tool on the plate and fit the plate into place Specific tooling 19 90 65 00 Tool for clutch plate fitting cen tring Engine V750 IE Engine ENG 51 ...

Page 52: ...plate flywheel and tighten the screws to the prescribed torque Clutch bell fitting Fit the clutch shaft Position the clutch bell gasket and fit the clutch bell into place See also Assembling the clutch shaft Engine Engine V750 IE ENG 52 ...

Page 53: ...ternal screws and tighten them to the prescri bed torque Tighten the clutch shaft nut using the suitable tool and squash Specific tooling 19 90 71 60 Clutch shaft locking equipment Insert the breather cap Engine V750 IE Engine ENG 53 ...

Page 54: ...he shaft with the larger diameter facing the control lever Head and timing HEAD CYLINDER pos Description Type Quantity Torque Notes 1 Central stud bolt M8x143 2 20 Nm 14 75 lb ft Loctite 542 2 Short stud bolt M10x182 4 42 Nm 30 98 lb ft Engine Engine V750 IE ENG 54 ...

Page 55: ... ft 8 Outer head cover screws M6x52 5 8 8 10 Nm 5 90 7 37 lb ft TIMING SYSTEM pos Description Type Quantity Torque Notes 1 Tone wheel screw M8x22 1 25 Nm 18 44 lb ft 2 Timing system gear screws 2 25 Nm 18 44 lb ft Loctite 243 3 Chain tensioner screw M6x16 1 10 Nm 7 38 lb ft 4 Valve clearance adjuster screw M6x1 4 10 Nm 7 38 lb ft Removing the head cover Remove the spark plug cover Disconnect the s...

Page 56: ...Remove the gasket Check that the mating faces that contact the heads are not damaged or blistered Removing the cylinder head The following instructions refer to one head but apply to both Remove the head cover Unscrew the spark plug Engine Engine V750 IE ENG 56 ...

Page 57: ...e rocker cam tower See also Removing the head cover Remove the rocker cam tower and col lect the plates Remove the rocker rods Remove the outer nuts that fix the head to the cylinder and collect the washer Engine V750 IE Engine ENG 57 ...

Page 58: ...inder Remove the complete head from the cylinder Remove the cylinder head gasket 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 Engine Engine V750 IE ENG 58 ...

Page 59: ... Remove the circlips slide off the two rockers and the oil delivery fitting See also Removing the head cover Engine V750 IE Engine ENG 59 ...

Page 60: ...00 Tool for valve removal and refitting 19 92 78 00 Adapter bushing for valve remov ing tool Close the tool to compress the spring and then hit the tool head with a mallet so that the two cotters get detached from the upper cap Unscrew the tool and remove it from the head Slide off the upper cap the spring and finally the valve Engine Engine V750 IE ENG 60 ...

Page 61: ...x tract the lower cap of the springs VALVE GUIDES MUST BE REPLACED WHEN THEY ARE WORN TO THE POINT THAT REPLACING THE VALVE ALONE IS NOT ENOUGH TO ELIMINATE CLEARANCE BE TWEEN VALVE STEM AND VALVE GUIDE BORE Engine V750 IE Engine ENG 61 ...

Page 62: ...s not exceedingly worn Check the rocker to valve and rocker to rod contact surfaces Inspecting the springs and half cones With the assembly installed retainers springs valves and cotters in the heads the compressed ex ternal springs should measure 36 mm 1 4173 in Please note that the valves should have a remaining lift of 1 mm 0 039 in when fully open before the internal spring becomes fully compr...

Page 63: ... Quantity Inside diameter 17 8 0 2 mm 0 7007 0 0079 in Wire diameter 3 4 0 03 mm 0 1338 0 0012 in Unloaded length 43 6 mm 1 7165 in Compressed length 27 5 mm 1 0827 in Test length L1 36 mm 1 4173 in Test length L2 28 mm 1 1024 in Engine V750 IE Engine ENG 63 ...

Page 64: ...he cylinder head CAUTION VALVE SEAT GRINDING AFTER VALVE GUIDE REPLACEMENT OR WHEN THE VALVES LEAK Once you have chosen the pilot tool insert it into the valve guide seat and lock it in place Choose the proper cutter to suit valve seat diameter and angle Insert the cutter into the pilot tool and push it down gently until it contacts the valve seat Engine Engine V750 IE ENG 64 ...

Page 65: ...nto the cutter and turn clockwise while pressing lightly achieving an even valve contact sur face Repeat the procedure using the suita ble cutter to achieve the correct valve seat sealing surface Engine V750 IE Engine ENG 65 ...

Page 66: ...he head to approximately 60 C 140 F before proceeding Specific tooling 19 92 60 20 Punch for cap installation on valve guide Insert the valve guides into their seats and bore them out to the size indicated in the table with a reamer VALVE AND GUIDE COUPLING DATA VALVE GUIDE INSIDE Ø mm in VALVE STEM Ø mm in FITTING CLEARANCE mm in Intake 5 500 5 520 0 2165 0 2173 5 480 5 465 0 2157 0 2151 0 020 0 ...

Page 67: ...in C nominal Ø mm in D mm in 32 0 32 25 1 2598 1 2697 34 1 3386 1 42 0 0559 1 0 0394 EXHAUST A Ø mm in B nominal Ø mm in C nominal Ø mm in D mm in 27 72 27 97 1 0913 1 1012 30 1 1811 1 6 0 0630 1 14 0 0448 Engine V750 IE Engine ENG 67 ...

Page 68: ...nal slot is pointing to the oil delivery passage WHEN REFITTING PAY SPECIAL ATTENTION TO THE MOUNTING POSITION OF THE WASHERS Insert the oil delivery fitting and the rockers on the shaft and lock them in place with the circlips Engine Engine V750 IE ENG 68 ...

Page 69: ...the rods from a small height on a flat sur face on impact you should hear a sharp clank this means the pads have no clearance Adjusting valve clearance Bring the piston of the left cylinder to top dead centre making sure that the reference mark on the crankshaft gear is up on the perpendicular axis Place the camshaft with the reference pin of the gear pointing downwards Engine V750 IE Engine ENG 6...

Page 70: ...dica ted values When the valve clearance values intake and exhaust respective ly are different from the ones indicated below adjust them by loosening the lock nut and operate on the set screw with a screwdriver Intake 0 15 mm 0 0059 in when cold Outlet 0 20 mm 0 0079 in when cold Engine Engine V750 IE ENG 70 ...

Page 71: ... COVER pos Description Type Quantity Torque Notes 1 TCEI screw M6x25 10 10 Nm 7 37 lbf ft 2 TCEI screw M6x30 2 10 Nm 7 37 lbf ft 3 Alternator cover screws M6x35 5 10 Nm 7 37 lbf ft Loctite 243 Engine V750 IE Engine ENG 71 ...

Page 72: ...38 lb ft 4 Valve clearance adjuster screw M6x1 4 10 Nm 7 38 lb ft TIMING SYSTEM COVER REMOVAL Remove alternator and cover to get ac cess to the timing system Undo the fixing screws and remove the timing system cover with its gasket REFITTING THE TIMING SYSTEM COVER Insert the gasket position the timing system cover and tighten to the prescribed torque using a torque wrench Engine Engine V750 IE EN...

Page 73: ...system cover Remove the chain tensioner Collect the washer See also Timing Chain removal Remove the tone wheel Remove the two screws slide the tim ing gear off the shaft remove chain and oil pump gear Collect the washer Engine V750 IE Engine ENG 73 ...

Page 74: ...nic wheel Remove the engine unit from the chas sis Remove the timing system cover Remove the chain tensioner Unscrew and remove the tone wheel fixing screw and collect the washer See also Removing the chain tensioner Timing Engine Engine V750 IE ENG 74 ...

Page 75: ...eel making sure it locates correctly on the camshaft see slot and tighten to the prescribed tor que using a torque wrench Cam timing Bring the piston of the left cylinder to top dead centre making sure that the reference mark on the crankshaft gear is up on the perpendicular axis Engine V750 IE Engine ENG 75 ...

Page 76: ...r pointing downwards Insert the oil pump shaft pin key Fit the two gears with the timing chain after installation check the position of the reference notches and tighten the screws to the prescribed torque with a torque wrench Engine Engine V750 IE ENG 76 ...

Page 77: ... Tighten the oil pump nut while holding the oil pump shaft steady Fit the chain tensioner and tighten to the prescribed torque using a torque wrench Engine V750 IE Engine ENG 77 ...

Page 78: ...4 42 Nm 30 98 lb ft 3 Long stud bolt M10x214 4 42 Nm 30 98 lb ft 4 Nuts pre tightening M10x1 5 4 25 Nm 18 44 lb ft 4 Nuts tightening M10x1 5 4 42 Nm 30 98 lb ft 5 Column nut 4 25 Nm 18 44 lb ft 6 Nut 2 28 Nm 20 65 lb ft 7 Internal Head cover screws M6x25 4 8 10 Nm 5 90 7 37 lb ft 8 Outer head cover screws M6x52 5 8 8 10 Nm 5 90 7 37 lb ft Engine Engine V750 IE ENG 78 ...

Page 79: ... stud bolts Remove the gasket from the stud bolts See also Removing the cylinder head Remove the O ring of the lubrication duct of the thermal unit CAUTION PAY PARTICULAR ATTENTION TO ENSURE THAT THE O RING DOES NOT FALL INSIDE THE CRANKCASE Engine V750 IE Engine ENG 79 ...

Page 80: ...CIRCLIP GROOVES Checking the cylinder After checking for scoring check cylin der surface wear using a dial gauge graduated in hundredths of a millime tre Measure the inner diameter of the cyl inders at three different heights turn the dial gauge graduated in hun dredths of a millimetre 90 and repeat the measurements set the dial gauge graduated in hundredths of a millimetre to zero using a ring ga...

Page 81: ...llime tre Measure the inner diameter of the cyl inders at three different heights turn the dial gauge graduated in hun dredths of a millimetre 90 and repeat the measurements set the dial gauge graduated in hundredths of a millimetre to zero using a ring gauge before measuring Key 1 1st measurement 2 2nd measurement 3 3rd measurement 4 measurement for classification Engine V750 IE Engine ENG 81 ...

Page 82: ...s into the cylinder and check clearance at end gaps using a feeler gauge Top piston ring mm 0 20 0 35 in 0 0079 0 0138 Intermediate piston ring mm 0 35 0 55 in 0 0138 0 0216 oil scraper ring mm 0 20 0 70 in 0 0079 0 0275 PISTON RINGS AND OIL SCRAPER REFITTING Insert the piston rings paying attention to their mounting direction and end gap arrangement the end gaps must be approximately 120 degrees ...

Page 83: ...retaining clip into the piston and fit the specified pin insertion tool to the piston Position the piston with the tool attach ed on the connecting rod in order to install the pin When finished remove the tool and in sert the second snap ring that closes the piston pin seat after protecting the cylinder seat CAUTION MOUNTING POSITION IS INDICATED BY AN ARROW POINTING IN THE DIRECTION OF TRAVEL Eng...

Page 84: ...ston ring end gaps are approximately 120 degrees from each other Position the O ring on the lubrication duct of the thermal unit Fit a new gasket Place a commercially available appro priate ring clamp on the piston Engine Engine V750 IE ENG 84 ...

Page 85: ...in 80 000 80 010 3 1496 3 1500 80 010 80 020 3 1500 3 1504 80 020 80 030 3 1504 3 1508 When fitting new units grade D E F cylinders must be matched with corresponding grade D E F pistons Fitting clearances between piston and cylinders 0 050 0 070 mm 0 0020 0 0027 in Selecting the piston Check the diameter of the piston at the specified height perpendicular to the pin axis Selection values refer to...

Page 86: ... THICKNESS OF THE NEW PAINTED ANTI FRICTION COATING 0 015 0 020 mm 0 00059 0 00079 in PIN AND PISTON EYE COUPLING DATA PIN OUTER Ø mm in PISTON EYE ø mm in FITTING CLEARANCE and INTERFERENCE FIT mm in 21 994 21 998 0 8659 0 8661 22 000 22 006 0 8661 0 8664 From 0 006 mm 0 00024 in clearance to 0 002 mm 0 0008 in interference fit Installing the cylinder head Insert the new gasket and fit the cylin ...

Page 87: ... Fit the rocker lower spacers the rocker control rods the rockers and the upper spacers with their nuts Engine V750 IE Engine ENG 87 ...

Page 88: ... Tighten the nuts to the prescribed tor que following a crisscross pattern Installing the head cover Replace the head cover gaskets and refit the covers to the heads Engine Engine V750 IE ENG 88 ...

Page 89: ... Tighten the screws following a criss cross pattern with a torque wrench set to the prescribed torque Engine V750 IE Engine ENG 89 ...

Page 90: ...n Type Quantity Torque Notes 1 Column nuts 4 42 Nm 30 98 lbf ft 2 Nut M8x1 25 6 22 Nm 16 22 lbf ft 3 TCEI screw M6x25 12 10 Nm 7 37 lbf ft 4 Oil drainage plug M10x1 1 40 Nm 29 5 lbf ft Spark plugs 2 30 Nm 22 13 lbf ft Engine Engine V750 IE ENG 90 ...

Page 91: ... Flywheel screws 6 42 Nm 30 98 lbf ft Loctite 243 Splitting the crankcase halves Unscrew the four long nuts from inside the crankcase and the six external nuts Insert a rod into the seat of the linkage joining engine and chassis then tap the rod lightly with a plastic mallet until separating the two crankcase halves Engine V750 IE Engine ENG 91 ...

Page 92: ...g face Remove the crankshaft together with connecting rods and half bearings Unscrew the oil pressure sensor from the upper crankcase and remove the retaining bushing of the camshaft remove the shaft and the tappets noting their positions Engine Engine V750 IE ENG 92 ...

Page 93: ...ng the crankshaft Remove the crankshaft connecting rods Unscrew the oil plug and thoroughly clean the oilway and oil passages de livering oil to connecting rods and main journals Engine V750 IE Engine ENG 93 ...

Page 94: ...r with the connecting rods from the upper crankcase loosen the screws and separate connecting rod from small end noting the reference marks and mount ing direction Remove the half bearings from con necting rods and small ends CAUTION REPEAT THE PROCEDURE FOR THE OTHER CONNECT ING ROD Engine Engine V750 IE ENG 94 ...

Page 95: ...or scored Remove any liquid gasket residues with thry chlorethylene Check that the threads of the stud bolts are not dented or stripped if they are replace the stud bolt or stud bolts Blow all oil galleries of the two crank case halves with compressed air Engine V750 IE Engine ENG 95 ...

Page 96: ...130 47 142 mm 1 8555 1 8560 in Total thickness for flywheel side main bearings 2 044 2 050 mm 0 0805 0 0807 in Clearance between shaft and flywheel side bearing 0 007 0047 mm 0 0003 0 0018 in Flywheel side main journal diameter 39 995 40 011 mm 1 5746 1 5752 in Thickness of thrust half ring on flywheel side main bearing 2 310 2 360 mm 0 0909 0 0929 in Side thrust clearance of crankshaft in crankca...

Page 97: ... the connecting rod for notches due to seizing or deep scoring replace as required Seat diameter 43 657 43 670 mm 1 7188 1 7193 in Shaft diameter 39 995 40 001 mm 1 5746 1 5748 in Clearance between shaft and connecting rod bearing at 90 away from mating faces min 0 020 0 0008 in max 0 061 0 0024 in CONNECTING ROD BEARING THICKNESSES STANDARD stock production A mm in STANDARD stock production B mm ...

Page 98: ...n in the crankshaft seat and tighten the screws to the pre scribed torque CONNECTING ROD SHIMS CHECK Check that the mounting clearance between con necting rod shims and crankshaft shoulders is within the specified values 0 265 0 515 mm 0 0104 0 0203 in Refitting the crankcase halves Insert the tappets after lubricating them properly Engine Engine V750 IE ENG 98 ...

Page 99: ...in the upper crankcase lubricate and insert locking the camshaft locking fitting Insert the timing system side and fly wheel side half bearings with their thrust washers into the seats in the up per crankcase Engine V750 IE Engine ENG 99 ...

Page 100: ...Insert the seal ring after lubricating it on the crankshaft and the assembly onto the engine crankcase making sure that the connecting rods locate correctly into their seats Engine Engine V750 IE ENG 100 ...

Page 101: ...ed liquid gasket to the crank case mating faces Join the two crankcase halves and tap lightly with a mallet to ensure that the two mating faces adhere together firm ly tighten the four central stud bolts and the external nuts following a criss cross pattern Engine V750 IE Engine ENG 101 ...

Page 102: ...e Quantity Torque Notes 1 Column nuts 4 42 Nm 30 98 lbf ft 2 Nut M8x1 25 6 22 Nm 16 22 lbf ft 3 TCEI screw M6x25 12 10 Nm 7 37 lbf ft 4 Oil drainage plug M10x1 1 40 Nm 29 5 lbf ft Spark plugs 2 30 Nm 22 13 lbf ft Engine Engine V750 IE ENG 102 ...

Page 103: ...Oil pressure sensor 1 30 Nm 22 13 lbf ft 3 Oil pump screws M6x35 3 10 Nm 7 38 lbf ft Loctite 648 4 Oil filter screw 1 6 Nm 4 43 lbf ft Removing After removing the timing system re move the oil pump from the crankcase unscrewing the Allen screws Removal procedure is as follows Engine V750 IE Engine ENG 103 ...

Page 104: ...ove the retaining key Slide off the pump drive shaft with the internal rotor attached Slide off the external rotor Slide off the bearings and their inner housing from pump body Engine Engine V750 IE ENG 104 ...

Page 105: ...oil pump body are not scored damaged or dented Pump body specifications External rotor seat Ø 40 650 40 675 mm 1 6004 1 6014 in Pump drive shaft bore Ø 12 016 12 043 mm 0 4730 0 4741 in Needle bearing seat Ø 21 972 21 993 mm 0 8650 0 8659 in Engine V750 IE Engine ENG 105 ...

Page 106: ...mm 0 9529 0 9539 in thickness 14 960 14 990 mm 0 5890 0 5902 in INTERNAL ROTOR Check that the inner and outer surfaces and the flat faces are not scored damaged or dented if they are replace both rotors Internal rotor specifications outer Ø 29 745 29 770 mm 1 1711 1 1720 in inner Ø 12 000 12 018 mm 0 4724 0 4731 in thickness 14 960 14 990 mm 0 5890 0 5902 in NEEDLE BEARINGS Make sure the needle ro...

Page 107: ...3933 0 3937 in FITTING CLEARANCES between pump body and external rotor 0 080 0 135 mm 0 0031 0 0053 in between internal rotor bore and drive shaft 0 016 0 061 mm 0 0006 0 0024 in between internal body bore and drive shaft 0 016 0 061 mm 0 0006 0 0024 in Installing Assemble the oil pump and refit it to the crankcase paying attention to the two alignment dowels Tighten the Allen screws to the prescr...

Page 108: ...Removing the oil sump Remove the engine oil filter Unscrew the screws fixing the oil sump to the engine crankcase remove the oil sump and the gasket Engine Engine V750 IE ENG 108 ...

Page 109: ...tor Straighten the safety plate remove the mesh filter retaining screw from the oil sump and remove the mesh filter Check that the mesh filter is not dirty wash and blow with compressed air if needed Engine V750 IE Engine ENG 109 ...

Page 110: ... screw then tighten the screw Bend the safety plate Position the gasket between the sump and crankcase always change the gasket Pay attention during the pro cedure if wrongly installed the gasket will prevent proper oil circulation Engine Engine V750 IE ENG 110 ...

Page 111: ...ribed tor que using a torque wrench Insert the filter cartridge and tighten the screw to the prescribed torque Pressure reducer valve REMOVAL Unscrew the regulating valve mounted on the threaded hole in the crankcase using a suitable wrench Engine V750 IE Engine ENG 111 ...

Page 112: ...FITTING Insert the valve first and then the spring apply threadlocker to the screw and tighten to the prescribed torque Engine Engine V750 IE ENG 112 ...

Page 113: ...in 73 74 Chain tensioner 73 74 Clutch 31 32 46 47 49 52 Crankcase 90 91 95 98 Crankshaft 90 93 96 Cylinder 56 58 64 79 80 84 86 E Exhaust H Head cover 55 57 59 88 O Oil sump 108 110 S Starter motor 45 46 T Throttle body ...

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