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Generator removal

ALTERNATOR COVER REMOVAL

•

Remove the alternator cover fixing

screws

•

Remove the alternator cover.

•

Remove the gasket.

ROTOR REMOVAL

•

From the clutch side, partially unscrew

the two fixing screws of the clutch

plate, as indicated, to allow the correct

positioning of the specific clutch lock

tool.

Specific tooling

021001Y

Clutch retainer tool

Engine

Engine V85 E4

ENG - 48

Содержание V85 E4

Страница 1: ...SERVICE STATION MANUAL 2Q000383 Engine V85 E4...

Страница 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 bin...

Страница 3: ...d 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...

Страница 4: ......

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

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

Страница 7: ...Tightening torque 2 Nm 1 48 lb ft 2 Nm 1 48 lb ft 3 Nm 2 21 lbf ft 3 Nm 2 21 lbf ft CAUTION THE SCREWS WITH THREAD LOCK SEALANT PRE IMPREGNATED MUST BE REPLACED WITH NEW SCREWS AFTER THEY HAVE BEEN LO...

Страница 8: ...64 8 11 lb ft Pre applied Loct alternatively Loct DRI LOC 211 3M SCOTCH GRIP 2510 8 Central head stud bolts M8 2 9 11 Nm 6 64 8 11 lb ft Pre applied Loct alternatively Loct DRI LOC 211 3M SCOTCH GRIP...

Страница 9: ...ex socket screws M5x12 8 6 8 Nm 4 42 5 90 lb ft 2 Head covers screws M6 6 9 11 Nm 6 64 8 11 lb ft 3 Rounded head torx screws for spark plugs cable clamp on head covers M4 4 2 6 3 1 Nm 1 92 2 29 lb ft...

Страница 10: ...8 11 lb ft 4 Camshaft retainer plate torx rounded head screws M5x12 2 6 7 Nm 4 42 5 16 lb ft Pre applied Loct alternatively 3M SCOTCH GRIP 2353 5 Rocker axles forks hex head flanged screws M5x12 4 5...

Страница 11: ...ce with MOLYCOTE GRAPID PLUS SPRAY grease 8 Stud bolt fixing nut final tightening M8 2 88 92 14 18 Nm 10 32 13 28 lbf ft Lubricate the threads and the support surface with MOLYCOTE GRAPID PLUS SPRAY g...

Страница 12: ...10 Nm 7 37 lb ft Lubricate the thread and underhead with Pankl PLB 19 2 Connecting rods screws pre tight ening 2nd coupling M8 4 20 Nm 14 75 lbf ft Lubricate the thread and underhead with Pankl PLB 19...

Страница 13: ...hreaded pin for ground cable screw M8x30 1 9 11 Nm 6 64 8 11 lb ft Loct 243 5 Bearing stoppers countersunk hex head screws M6x12 5 9 11 Nm 6 64 8 11 lb ft Pre applied Loct alternatively 3M SCOTCH GRIP...

Страница 14: ...r ground cable screw M8x30 1 9 11 Nm 6 64 8 11 lb ft Loct 243 5 Bearing stoppers countersunk hex head screws M6x12 5 9 11 Nm 6 64 8 11 lb ft Pre applied Loct alternatively 3M SCOTCH GRIP 2353 or Loct...

Страница 15: ...ription Type Quantity Torque Note 1 Bearing stoppers countersunk hex head screws M6x12 2 9 11 Nm 6 64 8 11 lb ft Pre applied Loct alternatively 3M SCOTCH GRIP 2353 or Loct DRI LOC 2045 BLU Engine V85...

Страница 16: ...ssure valve cap M18 1 20 25 Nm 14 75 18 44 lb ft 7 Oil scraper plate notched cylindrical head screws M5x10 4 3 4 Nm 2 21 2 95 lb ft Pre applied Loct alternatively 3M SCOTCH GRIP 2353 8 Cooling jet tor...

Страница 17: ...Oil pressure valve cap M18 1 20 25 Nm 14 75 18 44 lb ft 7 Oil scraper plate notched cylindrical head screws M5x10 4 3 4 Nm 2 21 2 95 lb ft Pre applied Loct alternatively 3M SCOTCH GRIP 2353 Loctite 2...

Страница 18: ...natively Loct DRI LOC 2040 or 3M SCOTCH GRIP 2353 3 Bearing stopper countersunk hex head screws M6x12 2 9 11 Nm 6 64 8 11 lb ft Pre applied Loct alternatively 3M SCOTCH GRIP 2353 or Loct DRI LOC 2045...

Страница 19: ...tator SHC screws M6x20 3 9 11 Nm 6 64 8 11 lb ft Loct 243 2 Flywheel flanged hex head screw M14x30 1 114 125 Nm 84 08 92 19 lb ft 3 Flanged hex head screws for cable clamp plate on the generator s cov...

Страница 20: ...SECONDARY AIR SYSTEM Pos Description Type Quantity Torque Note 1 Secondary air covers SHC screws M5 4 3 4 Nm 2 21 2 95 lb ft Characteristics Engine V85 E4 CHAR 20...

Страница 21: ...INDEX OF TOPICS SPECIAL TOOLS S TOOLS...

Страница 22: ...rt plate 020382Y Tool to extract valve cotters GU19927100 Tool for mounting seal ring on flange on the flywheel side 020995Y Rocker arm centring pin 020128Y Piston fitting ring 020996Y Piston protrusi...

Страница 23: ...tion 020713Y Flywheel extractor 020976Y Clutch control dust guard mounting punch 021020Y Clutch housing oil seal mounting punch 021001Y Clutch retainer tool 021002Y Clutch centring Engine V85 E4 Speci...

Страница 24: ...INDEX OF TOPICS ENGINE ENG...

Страница 25: ...haft 6 Floating bushing 7 Main shaft thrust washer 8 3rd and 4th speed sliding gear on main shaft 9 Circlip for the shaft 10 Thrust washer 11 5th speed gear on main shaft 12 Floating bushing 13 Main s...

Страница 26: ...ng bushing 25 4th speed gear on transmission shaft 26 Floating bushing 27 Thrust washer 28 Circlip for the shaft 29 5th speed gear on transmission shaft 30 Circlip for the shaft 31 Thrust washer 32 1s...

Страница 27: ...ed from the engine crankcase side Remove the complete gearbox screw Gearbox shafts Disassembling the gearbox Remove the 12 fixing screws of the gearbox engine side Remove the fastening screw of the ge...

Страница 28: ...cover with a few mallet strokes CAUTION CAREFULLY CLEAN THE THREEBOND FROM THE CONTACT SURFACES BEFORE APPLYING A NEW LAYER OF THREEBOND 1207B DURING THE REASSEMBLY OF THE GEARBOX Having removed all i...

Страница 29: ...ar box crankcase cover very well with a hair dryer It will then be possible to re move the bearings by knocking the crankcasings on a surface If necessa ry use a dummy ball bearing extractor If necess...

Страница 30: ...rks with shaft Remove the complete gear unit To dismantle the main shaft proceed as follows Remove the shim washer 1 Remove the gear of the 2nd gear 2 Using the appropriate jaws lock the primary shaft...

Страница 31: ...Remove the spacer 4 Remove the gear of the 6th gear 5 Remove the bushing 6 Remove the spacer 7 Engine V85 E4 Engine ENG 31...

Страница 32: ...move the gear of the 3 4th gear 8 Using the appropriate jaws lock the primary shaft in a vice and remove the circlip 9 Remove the spacer 10 Remove the gear of the 5th gear 11 Engine Engine V85 E4 ENG...

Страница 33: ...asher 13 from the main shaft 14 Removing the secondary shaft CAUTION FIT NEW CIRCLIPS WHEN REASSEMBLING Disassemble the secondary shaft as follows Remove the shim washer 1 Remove the gear of the first...

Страница 34: ...Remove the bushing 3 Remove the shim washer 4 Remove the seeger ring 5 Remove the gear of the 5th gear 6 Engine Engine V85 E4 ENG 34...

Страница 35: ...Remove the seeger ring 7 Remove the shim washer 8 Remove the gear of the 4th gear 9 Remove the bushing 10 Engine V85 E4 Engine ENG 35...

Страница 36: ...Remove the gear of the 3rd gear 11 Remove the bushing 12 Remove the shim washer 13 Remove the seeger ring 14 Engine Engine V85 E4 ENG 36...

Страница 37: ...Remove the gear of the 6th gear 15 Remove the seeger ring 16 Remove the shim washer 17 Remove the gear of the 2nd gear 18 Engine V85 E4 Engine ENG 37...

Страница 38: ...esmodromic demounting Remove the fork carrier shaft 1 Remove the desmodromic shaft 2 The forks are marked with a serial number that indicated the correct posi tioning Remove the upper fork No 1 3 Engi...

Страница 39: ...haft the secondary shaft fork travel shaft and the forks gearbox selector At this point the clutch shaft can be re moved with a few mallet taps paying attention to retrieve the shimming washer Remove...

Страница 40: ...g this measurement use the corresponding number of support washers B identified in the table below SUPPORT WASHERS SELECTION A 10 SPRING WASHERS PACK FREE THICKNESS B SUPPORT WASHERS QUANTITY 26 000 2...

Страница 41: ...ification Desc Quantity 1 Minimum wear limit of the rotation point on the gearbox cover bearing 19 975 mm 0 7864 in 2 Minimum wear limit of the rotation point on the gearbox cover base 24 987 mm 0 983...

Страница 42: ...earings on the gearbox crankcases A special punch must be used to insert the bearings on the seats of the pri mary secondary shaft with lubrication duct Specific tooling GU19926500 Punch for transmiss...

Страница 43: ...rews of the gear box engine side and then tighten them to the prescribed torque including the screw opposite the cardan side previ ously tightened manually After inserting the two half cones 1 on the...

Страница 44: ...related slid ing washers 5 and the external body 6 Gear selector Removing the gear selector Remove the desmodromic shaft first and then the complete gear selector shaft 1 Remove the spring from the i...

Страница 45: ...Remove the seeger ring 4 Remove the seeger ring 5 Remove the washer 6 Remove the bushing 7 Engine V85 E4 Engine ENG 45...

Страница 46: ...r spring 8 Remove the ring 9 Remove the bushing 10 WARNING DURING REFITTING PAY ATTENTION TO THE CORRECT POSITIONING OF THE BUSHING AS THE SIDES ARE NOT SYMMETRICAL Remove the index lever 11 Engine En...

Страница 47: ...lector return spring 13 Generatore Rimozione sensore giri NOTE PROCEDURE VALID ONLY FOR E4 VEHICLES Undo and remove the fixing screw of the sensor Remove the timing system cover sen sor Engine V85 E4...

Страница 48: ...ve the alternator cover Remove the gasket ROTOR REMOVAL From the clutch side partially unscrew the two fixing screws of the clutch plate as indicated to allow the correct positioning of the specific c...

Страница 49: ...ed pin 2 of the tool and pro ceed with the rotor removal Specific tooling 020713Y Flywheel extractor NOTE PROCEDURE VALID ONLY FOR E4 VEHICLES OIL SEAL REMOVAL Operating in the alternator cover to re...

Страница 50: ...STATOR REMOVAL Remove the stator wiring harness lock plate Removing the three stator fixing screws makes it possible to disconnect it NOTE PROCEDURE VALID ONLY FOR E5 VEHICLES STATOR REMOVAL Remove t...

Страница 51: ...FOR E4 VEHICLES During refitting of the flywheel cover it is necessary to apply a great amount of threebond on the cable grommet of the stator before placing it in its seat Check that plentiful three...

Страница 52: ...AUTION To comply with the strict MISFIRE monitoring requirements of by the EURO 5 regulations a new tone wheel and a new integrated Pick Up have been included in the stator s wiring harness When the M...

Страница 53: ...ve hicle at a standstill accelerate three times over 6500 rpm Switch off the panel and wait for at least one minute Power Latch CAUTION The procedure is successful ONLY if the vehicle s speed stays a...

Страница 54: ...rrect positioning of the spe cific clutch lock tool Specific tooling 021001Y Clutch retainer tool Using one of the fixing screws of the gearbox assembly secure the specific tool Remove the 6 fixing sc...

Страница 55: ...Remove the clutch disc Remove the retainer ring Remove the thrust plate Remove the 6 fixing screws of the lock ing plate Engine V85 E4 Engine ENG 55...

Страница 56: ...omplete Remove the spacer plate Checking the clutch plates Clutch disc Make sure that the clutch plate is not scratched or badly worn Check the flexible springs and the thickness of the clutch disc Ch...

Страница 57: ...hing where the starter mo tor pinion works is not chipped or scratched oth erwise replace it Assembling the clutch Insert the spacer plate on the crank shaft Insert the complete clutch lock Place the...

Страница 58: ...e 6 fastening screws complete with washers and tighten to the pre scribed torque Insert the thrust plate cap Lock the thrust plate using the special lock ring Place the clutch plate Engine Engine V85...

Страница 59: ...the six fastening screws at the recommended torque Bushing selection CRANKSHAFT CRANKCASE BUSHINGS The crankcase class is stamped in the following locations Alternator side on the upper crankcase in...

Страница 60: ...7 in Class 4 Bushing seat diameter 47 137 47 142 mm 1 8558 1 8560 in Four different crankcase classes are available 1 2 according to diameter of hole in half crankcase shells on alternator side 3 4 ac...

Страница 61: ...Specification Desc Quantity Class 1 Diameter 40 004 40 012 mm 1 5750 1 5753 in Class 2 Diameter 40 013 40 020 mm 1 5753 1 5756 in Class 3 Diameter 43 007 43 015 mm 1 6932 1 6935 in Class 4 Diameter 4...

Страница 62: ...Class 2 black black green green Class 3 green green yellow yellow Class 4 black black green green Head and timing Removing the head cover NOTE THE OPERATIONS FOR THE REMOVAL OF THE HEAD COVER ARE THE...

Страница 63: ...spark plug Bring the piston of the left cylinder to top dead centre Check that the punching of the crank shaft pinion 1 is aligned with the punching on the timing system sprock et 2 The punching on t...

Страница 64: ...LVE IS CHARACTERIZED BY THE PRES ENCE OF A CALIBRATED PAD THEREFORE PAY PAR TICULAR ATTENTION TO RECOVER IT DURING DISAS SEMBLY Remove the rocker being careful to re cover the Belleville spring NOTE R...

Страница 65: ...ker rods Remove the nut with relevant washer of the cylinder to the crankcase Unscrew and remove the compensa tion nut of the cam tower Undo and remove the fastening nuts of the cam tower Engine V85 E...

Страница 66: ...the three rubber O Rings CAUTION PAY SPECIAL ATTENTION THAT THE O RINGS DO NOT ACCIDENTALLY FALL INTO THE PROCESSING HOLES OF THE ROCKERS RODS Remove the complete head Remove the cylinder head gasket...

Страница 67: ...VEHICLES Undo and remove the secondary air valve cover Remove the secondary air valve check and if necessary replace the ex ternal rubber gasket Remove the internal filter paying atten tion to the dir...

Страница 68: ...d of the valve Specific tooling 020382Y Tool to extract valve cotters Close the tool to compress the spring and remove the two half cones from the upper cap Unscrew the tool and remove it from the hea...

Страница 69: ...LIMINATE CLEARANCE BE TWEEN VALVE STEM AND VALVE GUIDE BORE Remove the lower cap of the spring Checking the rocker arms Check that the bolt surface that con tacts the rockers is not exceedingly worn C...

Страница 70: ...ristic Coupling clearance between valve and guide WEAR LIMIT 0 06 mm 0 0024 in Valve stem distortion MEASURED ON 45 0 03 mm 0 0012 in Valve stem diameter MINIMUM WEAR VALUE 5 92 mm 0 2331 in Valve hea...

Страница 71: ...punching on the timing system sprock et 2 The punching on the timing sys tem sprocket can be viewed through the hole of the chain guide cap NOTE PROCEDURE VALID ONLY FOR E5 VEHICLES Use a feeler gauge...

Страница 72: ...eaching the prescribed values Tighten the lock nut Timing Rimozione ruota fonica NOTE PROCEDURE VALID ONLY FOR E4 VEHICLES Remove the timing system cover Remove the rotor Remove the screw fastening an...

Страница 73: ...Remove the chain tensioner Chain removal Remove the timing system cover the rotor and the tone wheel Remove the three fixing screws of the timing gear NOTE ONLY FOR E4 VEHICLES Remove the timing syst...

Страница 74: ...the oil pump gear Remove the timing chain removing the camshaft gear and the oil pump gear at the same time NOTE PAY ATTENTION TO THE CENTRING PIN OF THE OIL PUMP GEAR Retrieve the rear chain guide ca...

Страница 75: ...camshaft Remove the camshaft extracting it from the crankcase NOTE PROCEDURE VALID ONLY FOR E5 VEHICLES Remove the big ends and the cylin ders Remove the bucket tappets from the engine crankcase Remo...

Страница 76: ...shaft NOTE PROCEDURE VALID ONLY FOR E4 VEHICLES Insert the camshaft into the crankcase Place the two fixing screws and tighten them to the prescribed torque NOTE PROCEDURE VALID ONLY FOR E5 VEHICLES I...

Страница 77: ...all Installazione piattello blow by Place the blow by cap on the camshaft making the holes and the special tim ing plug match Installazione catena For the installation of the timing chain it is necess...

Страница 78: ...sure that the reference mark on the crankshaft gear is up on the perpendicular axis and that the rocker have clearance After having placed the rear chain guide cap fit the timing system chain togethe...

Страница 79: ...THE CRANKSHAFT AND ON THE TIMING SYSTEM GEAR Using a thin tool refine the alignment of the oil pump pin with the milling on the gear of the pump itself Fit the safety plug Fit the knurled washer and...

Страница 80: ...it the front chain guide on the timing system sprocket and then insert the three fixing screws and tighten them to the recommended torque NOTE ONLY FOR E5 VEHICLES Fit the bulkhead on the camshaft fit...

Страница 81: ...the temperature sensor from the left cylinder NOTE ONLY FOR E5 VEHICLES Remove the gasket from the stud bolts Disassembling the piston Remove one of the two retainer rings from the pin paying attenti...

Страница 82: ...r 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 mil...

Страница 83: ...clearance between piston and cylinder G 83 953 83 960 mm 3 3052 3 3055 in 0 040 0 054 mm 0 0016 0 0021 in H 83 960 83 967 mm 3 3055 3 3058 in 0 040 0 054 mm 0 0016 0 0021 in L 83 967 83 974 mm 3 3058...

Страница 84: ...138 0 0217 in Oil scraper ring 0 18 mm 0 0071 in 0 20 0 70 mm 0 0079 0 0276 in Fit the piston ring to the cylinder Level the installed piston ring with the piston crown Measure piston ring port and re...

Страница 85: ...Installing the cylinder Check that the piston ring end gaps are approximately 120 degrees from each other Fit a new gasket Fit the existing temperature sensor on ly on the left cylinder NOTE ONLY FOR...

Страница 86: ...urement tool Fit the tool together with the dial gauge on the cylinder and tighten the fixing nuts Detect the deviation on the dial gauge Specific tooling 020996Y Piston protrusion measurement tool CA...

Страница 87: ...valve Insert the reed valve Fit the cover of the secondary air valve and tighten the screws to the prescri bed torque Fit the engine oil pressure sensor only in the left head and tighten it to the pr...

Страница 88: ...ngine head into place Place the three rubber O Rings par ticularly apply grease to the O Ring that will be inserted in the stud bolt in order to avoid damaging it Position the cam tower in its seat En...

Страница 89: ...wer to the prescribed torque Insert and tighten the compensation nut of the cam tower to the prescribed torque Position the washer with the relevant nut on the base of the cylinder and tighten to the...

Страница 90: ...ing pin align the rocker and the Belleville spring with the pin seat for easy insertion Specific tooling 020995Y Rocker arm centring pin Insert the rocker pin retainer fork on the pin and insert it in...

Страница 91: ...fork to the prescri bed torque Insert and tighten the spark plug to the prescribed torque Installing the head cover Fit the gasket on the head cover Place the head cover together with the gaskets on...

Страница 92: ...case crankshaft Splitting the crankcase halves Remove the bucket tappets the oil sump the filter and the overpressure valve Unscrew and remove the six external nuts and their washers Undo and remove t...

Страница 93: ...ft connecting rods Unscrew the oil plug and thoroughly clean the oilway and oil passages delivering oil to con necting rods and main journals See also Disassembling the connecting rod Disassembling th...

Страница 94: ...on timing system side WEAR LIMIT VALUE 40 004 mm 1 5750 in Main bushing seat diameter on timing system side MAXIMUM WEAR VALUE 43 67 mm 1 7193 in Thickness for main bushing on timing system side MAXI...

Страница 95: ...uantity Diameter connecting rod head seat MAXIMUM WEAR VAL UE 43 67 mm 1 7193 in Thickness of connecting rod head small ends MINIMUM WEAR VALUE 1 807 mm 0 0711 in Diameter of the small end with presse...

Страница 96: ...749 in B white 43 664 43 670 mm 1 7191 1 7193 in 40 003 40 011 mm 1 5749 1 5752 in CONNECTING ROD CRANKSHAFT ASSEMBLY CLASSES Connecting rod selection class Blue crankpin marking White crankpin markin...

Страница 97: ...NKSHAFT table Installing the crankshaft If it is necessary to replace the crankshaft or the connecting rods follow the reference table regard ing the couplings between the CONNECTING ROD weight class...

Страница 98: ...crankcase from the flywheel side paying attention to lubricate them in the friction area CAUTION THE MOUNTING DIRECTION OF THE THRUSTS IS UNIQUE Insert the seal ring after lubricating it on the cranks...

Страница 99: ...ts and the six external nuts together with washers Tighten all nuts to the prescribed torque proceeding with the cross order Removing Remove the timing system complete with oil pump gear Using a haird...

Страница 100: ...move the cover 1 from the pump 2 Working on the oil pump gear side re move the external rotor 3 Remove the internal rotor 4 Remove the safety pin 5 from the pump drive shaft Engine Engine V85 E4 ENG 1...

Страница 101: ...NAL ROTOR ROTOR SIDE Description Values External diameter WEAR LIMIT VALUE 40 54 mm 1 5961 in Internal diameter MAXIMUM WEAR VALUE 24 23 mm 0 9539 in Thickness of seat MAXIMUM WEAR VALUE 12 07 mm 0 47...

Страница 102: ...head the runs in the rotor is not damaged replace the shaft if needed Shaft specifications OIL PUMP DRIVE SHAFT Description Values Diameter for pump body seat MINIMUM WEAR VALUE 11 989 mm 0 4720 in D...

Страница 103: ...rt the external rotor 6 paying at tention to the punch mark that must be facing outwards After inserting the cover position the complete oil pump in place Insert the three oil pump retaining screws an...

Страница 104: ...Removing the oil sump Remove the engine oil filter fixing screw Remove the engine oil filter Remove the 14 fastening screws of the oil sump Remove the oil sump Engine Engine V85 E4 ENG 104...

Страница 105: ...Remove the gasket Remove the rose pipe Remove the cap and the relative cop per gasket Remove the spring Engine V85 E4 Engine ENG 105...

Страница 106: ...tting the oil sump Install the overpressure valve in the engine crankcase Insert the spring and afterwards the cap provided with a new copper gas ket tighten it to the prescribed torque Insert the ros...

Страница 107: ...ert and tighten the 14 fastening screws of the oil sump to the prescri bed torque Insert the engine oil filter together with the cover Insert and tighten the locking screw of the engine oil filter to...

Страница 108: ...e 92 94 98 Crankshaft 92 94 97 Cylinder 63 67 81 82 85 87 D Desmodromic drum 41 F Forks 41 H Head cover 62 91 M Magneto flywheel O Oil sump 103 104 106 P Pistons Primary shaft 29 S Secondary air syste...

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