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GEARBOX

4 - 25

Engine V1100

4.2.3.

REFITTING THE CLUTCH

Fit the following parts in 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. 12.91.18.01) to flywheel
and tool (part no. 30.90.65.10) compressing the clutch
springs.

Содержание Engine V1100

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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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