MOTO GUZZI V1100 Workshop Manual
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MOTO GUZZI V1100 Workshop Manual

MOTO GUZZI V1100 Workshop Manual

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Summary of Contents for MOTO GUZZI V1100

  • Page 1 Engine V1100 workshopmanual...
  • Page 2 INTRODUCTION Engine V1100 INTRODUCTION 0 - 1...
  • Page 3 INTRODUCTION Engine V1100 SUMMARY 0.1. INTRODUCTION .............................. 3 0.1.1. FOREWORD ............................. 3 0.1.2. REFERENCE MANUALS .......................... 4 0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS ..................5 0 - 2...

  • Page 4: Introduction

    DEPT., they will be glad to give you any information on the matter, or supply you with any detail on updates and technical changes applied to the vehicle. Moto Guzzi s.p.a. reserves the right to make changes to its products at any time, barring any such changes as may alter the essential features of a product as specified in the relevant manual.

  • Page 5: Reference Manuals

    INTRODUCTION Engine V1100 0.1.2. REFERENCE MANUALS PARTS CATALOGUES guzzi part# (description) GU077_00 OWNER'S MANUALS 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# (description) 8140894...

  • Page 6: Abbreviations/Symbols/Conventions

    INTRODUCTION Engine V1100 0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS = number < = less than > = greater than ≤ = less than or equal to ≥ = more than or equal to = approximately ∞ = infinity °C = degrees Celsius (centigrade) °F = degrees Fahrenheit ±...
  • Page 7 INTRODUCTION 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 = Twin Spark Ignition UPSIDE- DOWN = inverted fork = volt = watt Ø...
  • Page 8 GENERAL INFORMATION Engine V1100 GENERAL INFORMATION 1 - 1...

  • Page 9: Table Of Contents

    GENERAL INFORMATION Engine V1100 SUMMARY 1.1. STRUCTURE OF THE 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.

  • Page 10: Structure Of The Manual

    GENERAL INFORMATION Engine V1100 1.1. STRUCTURE OF THE MANUAL 1.1.1. CONVENTIONS USED IN THE MANUAL • This manual is divided in sections and subsections, each covering a set of the most significant components. Refer to the index of sections when consulting the manual.

  • Page 11: Safety Warnings

    GENERAL INFORMATION Engine V1100 1.1.2. SAFETY WARNINGS The symbols and warnings used throughout this manual have the following meanings: Safety warning. This symbol appears, whether in the manual or on the vehicle itself, to indicate a personal injury hazard. Non-compliance with the indications given in the messages preceded by this symbol may result in serious risks for your and other people’s safety and for the vehicle!

  • Page 12: General Rules

    GENERAL INFORMATION Engine V1100 1.2. GENERAL RULES 1.2.1. BASIC SAFETY RULES CARBON MONOXIDE Should it be necessary to perform some operations with the vehicle running, make sure to work outdoors or in a well- aerated room. Avoid starting the engine indoors.
  • Page 13 GENERAL INFORMATION Engine V1100 HYDROGEN AND BATTERY FLUID DANGER The battery electrolyte is a toxic, caustic substance containing sulphuric acid and thus able to cause severe burns in case of contact with the skin. Always wear tight gloves and protective clothes when handling this fluid.
  • Page 14 NOTE All bearings must rotate freely with no hard spots or noise. Replace any bearings that do not meet these requirements. Use GENUINE Moto Guzzi spare parts only. Use the specified lubricants and consumables. Where possible, lubricate a part before assembly.

  • Page 15: Dangerous Elements

    GENERAL INFORMATION Engine V1100 1.3. DANGEROUS ELEMENTS 1.3.1. WARNINGS FUEL DANGER The fuel used to operate engines is highly flammable and becomes explosive under particular conditions. Refuelling and engine servicing should take place in a well-ventilated area with the engine stopped.
  • Page 16 GENERAL INFORMATION Engine V1100 BRAKE FLUID NOTE This vehicle is fitted with front and rear disc brakes. Each braking system is operated by an independent hydraulic circuit. The information provided below applies to both braking systems. DANGER Do not use the vehicle in case brakes are worn out or do not work properly. The brakes are the parts that most ensure your safety and for this reason they must always be perfectly working.
  • Page 17 GENERAL INFORMATION Engine V1100 TYRES WARNING If tyres are excessively inflated, the vehicle will be hard, difficult and uncomfortable to ride. In addition, the roadworthiness, mainly on wet surfaces and during cornering, will be impaired. Flat tyres (insufficient pressure) can slip on the rim and make you lose the control of the vehicle.

  • Page 18: Running-In

    GENERAL INFORMATION Engine V1100 1.4. RUNNING-IN 1.4.1. RUNNING-IN Correct engine running-is essential to ensuring proper performance and durability. Twisty, hilly roads are ideal for an effective running-in of engine, suspension and brakes. During running-in, change speed. This will allow engine parts to be alternately loaded and unloaded, allowing them to cool down when unloaded.

  • Page 19: Position Of The Serial Numbers

    GENERAL INFORMATION Engine V1100 1.5. POSITION OF THE SERIAL NUMBERS 1.5.1. POSITION OF THE SERIAL NUMBERS These numbers are necessary for the registration of the vehicle. NOTE Do not alter the identification numbers if you do not want to incur severe penal and administrative sanctions; in particular, altering the frame number voids the warranty.
  • Page 20 TECHNICAL INFORMATION Engine V1100 TECHNICAL INFORMATION 2 - 1...
  • Page 21 TECHNICAL INFORMATION Engine V1100 SUMMARY 2.1. TECHNICAL INFORMATION..........................3 2.1.1. TECHNICAL DATA............................ 3 2.1.2. LUBRICANT TABLE ..........................4 2.1.3. TIGHTENING TORQUE SETTINGS ......................5 2.1.4. SPECIAL TOOLS ............................7 2 - 2...

  • Page 22: Technical Information

    TECHNICAL INFORMATION Engine V1100 2.1. TECHNICAL INFORMATION 2.1.1. TECHNICAL DATA ENGINE Type twin-cylinder, 90° V transversal, 4-stroke engine Number of cylinders Cylinder arrangement V, 90° Total displacement 1064 cu cm (65 cu in) Bore/stroke 92 x 80 mm (3.6 x 3.1 in).

  • Page 23: Lubricant Table

    TECHNICAL INFORMATION Engine V1100 2.1.2. LUBRICANT TABLE LUBRICANT PRODUCT Engine oil RECOMMENDED: RACING 4T 5 W 40 As an alternative to recommended oils, top brand oils meeting or exceeding CCMC G-4 A.P.I. SG specifications can be used. Transmission fluid RECOMMENDED:...

  • Page 24: Tightening Torque Settings

    TECHNICAL INFORMATION Engine V1100 2.1.3. TIGHTENING TORQUE SETTINGS DESCRIPTION HEAD UNIT head taper cap stud bolt M8x42 adjuster / / / 8-11 Hex.head screw DA M6x16 stainl.st. TBEI screw M6x25 stainl.st.flanged TBEI screw M5x16 oil/head temperature sensor M12x1.5 10-12 head temperature sensor casing M10x1.5...
  • Page 25 TECHNICAL INFORMATION Engine V1100 DESCRIPTION LUBRICATION UNIT TCEI screw DA M8x30 15-18 drilled screw M8x1.25 plug M18x1.5 plug M32x1.5 CRANKSHAFT UNIT connecting rod screw 60÷62 nut EBFM ZB MF25x1.5 FRAME UNIT ON ENGINE 8-12 TCEI screw DA M6x40 reduction IGNITION UNIT...

  • Page 26: Special Tools

    TECHNICAL INFORMATION Engine V1100 2.1.4. SPECIAL TOOLS Suitable special tools are necessary for correctly removing, refitting and adjusting. Unsuitable tools and/or improvised procedures could cause damages that might be avoided if the special tools are used. Following are the special tools especially designed for this vehicle.
  • Page 27 TECHNICAL INFORMATION Engine V1100 Pos. Description Part no. Belt tensioning tool 05.94.86.30 Front cover installation cone 05.91.17.30 Gearbox opening tool 05.91.25.30 Tool for removing the internal spark plug 05.90.19.30 Piston ring compression tool 05.92.80.30 Timing cover seal drift 05.92.72.30 Wrench for removing the cover on sump and filter 01.92.91.00...
  • Page 28 ENGINE Engine V1100 ENGINE 3 - 1...
  • Page 29 ENGINE Engine V1100 SUMMARY 3.1. REMOVING THE ACCESSORIES ........................3 3.1.1. REMOVING THE STARTER MOTOR ....................... 3 3.1.2. REMOVING THE BLOW-BY SYSTEM ...................... 4 3.2. GENERATOR ..............................6 3.2.1. REMOVING THE GENERATOR ....................... 6 3.2.2. INSTALLATION ............................10 3.3. TIMING SYSTEM............................14 3.3.1.

  • Page 30: Removing The Accessories

    ENGINE Engine V1100 3.1. REMOVING THE ACCESSORIES 3.1.1. REMOVING THE STARTER MOTOR • Loosen and remove the two screws and collect the washers. • Slide out the starter motor. 3 - 3...

  • Page 31: Removing The Blow-By System

    ENGINE Engine V1100 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. • Release the two clamps retaining the oil breather line. • Remove the two oil breather lines.
  • Page 32 ENGINE Engine V1100 • Loosen and remove the oil recovery line positioning screw. • Release the oil recovery line. • Remove the complete blow-by system. 3 - 5...

  • Page 33: Generator

    ENGINE Engine V1100 3.2. GENERATOR 3.2.1. REMOVING THE GENERATOR • Loosen and remove the six screws and collect the bushes. • Remove the cover. • Release and remove the eight screws. 3 - 6...

  • Page 34: Adjuster

    ENGINE Engine V1100 • Release and remove the two screws. • Loosen the nut and collect the screw. • Loosen the screw. • Loosen the nut and release the adjuster, so that generator can slide down. 3 - 7...
  • Page 35 ENGINE Engine V1100 • Completely unscrew and remove the screw. • Remove the belt and the generator complete with pulley. • Using an air gun, loosen and remove the nut and collect the spacer. • Slide out the lower pulley.
  • Page 36 ENGINE Engine V1100 • Remove the generator subframe. • Remove the seal, if necessary. 3 - 9...

  • Page 37: Installation

    ENGINE Engine V1100 3.2.2. INSTALLATION • If previously removed, change the seal 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). •...
  • Page 38 ENGINE Engine V1100 • 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.
  • Page 39 ENGINE Engine V1100 • Position 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.
  • Page 40 ENGINE 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. 3 - 13...

  • Page 41: Timing System

    ENGINE Engine V1100 3.3. TIMING SYSTEM 3.3.1. REMOVAL AND INSTALLATION REMOVAL • Remove the engine from the frame, see chassis manual, see (REFERENCE MANUALS). • Remove the generator following the instructions given in (REMOVAL). • Remove both heads, see (REMOVING THE HEADS).
  • Page 42 ENGINE Engine V1100 • Remove the key. • Loosen and remove the central nut securing the timing drive gear on the crankshaft and collect the washer. • Loosen and remove the nut and collect the washer. • Slide out the chain tensioner and collect the spring.
  • Page 43 ENGINE Engine V1100 • Slide out the pick-up ring and collect the dowel. • Loosen and remove the three screws and collect the washers. • Slide out the flange. • Slide out the tappets from their seats on either side.
  • Page 44 ENGINE Engine V1100 • Slide out the camshaft. REASSEMBLY NOTE For refitting the timing system, suitably heat the engine with a heater to be able to correctly fit the camshaft avoiding damages. • Follow the removal instructions in reverse order.

  • Page 45: Technical Data

    ENGINE Engine V1100 3.3.2. TECHNICAL DATA Timing data: INTAKE A Opens at 22° before TDC D Closes at 54° after BDC EXHAUST C Opens at 52° before BDC B Closes at 24° before TDC Intake valve clearance 0.10 mm (0.0039 in.).

  • Page 46: Timing

    ENGINE Engine V1100 3.3.3. TIMING To check the timing proceed as follows: • Set clearance between rocker arms and valves to mm 1.5 (0.059 in); • Set degree wheel hub (part no. 65.92.84.00) with degree wheel (part no. 19.92.96.00) onto crankshaft groove, insert the spacer and secure to crankshaft using the nut.
  • Page 47 ENGINE Engine V1100 • Check the timing, with reference to timing diagram, considering that: A – intake starts before TDC B – exhaust ends after TDC C – exhaust starts before BDC D - intake ends after BDC • Tighten the dial gauge and its support on right cylinder external spark plug hole.

  • Page 48: Measuring The Sensor Gap

    ENGINE Engine V1100 3.3.4. MEASURING THE SENSOR GAP • Loosen and remove the two screws and remove the sensor. • Fit a suitable flat washer on the sensor, measure its thickness. • Position the sensor to the timing cover and take it against the pick-up ring.
  • Page 49 ENGINE Engine V1100 • Measure the clearance between plate and cover using a feeler gauge. Take the flat washer thickness from this value to determine the gap between sensor and pick-up ring. • Remove the washer, smear the plate with suitable sealant, fit the sensor and tighten the screws to the specified torque.

  • Page 50: Oil Pump

    ENGINE Engine V1100 3.4. OIL PUMP 3.4.1. REMOVING THE OIL PUMP • Drain all engine oil. • Remove generator, (REMOVING GENERATOR). • Remove the timing system, see (REMOVING THE TIMING SYSTEM). • Loosen and remove the four oil pump securing screws (A).

  • Page 51: Heads

    ENGINE Engine V1100 3.5. HEADS 3.5.1. REMOVING THE HEAD COVERS NOTE The following procedure applies to both head covers. • Loosen and remove the eight screws and collect the bushes. • Remove the head cover and collect the gasket. NOTE Repeat the same procedure above described in reverse order to refit the head cover.

  • Page 52: Removing The Heads

    ENGINE Engine V1100 3.5.2. REMOVING THE HEADS NOTE The following procedure 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 left cylinder to TDC in combustion stage (valves closed).
  • Page 53 ENGINE Engine V1100 • Remove the rocker arm and collect 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 collect the washer.
  • Page 54 ENGINE Engine V1100 • Loosen and remove the four nuts and collect 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 the internal spark plug.
  • Page 55 ENGINE Engine V1100 • Loosen and remove the two screws and collect the two washers. • Slightly detach the head from the cylinder and remove the four O-rings. • Slide out the head and collect the gasket. 3 - 28...
  • Page 56 ENGINE Engine V1100 • Fit the special tool (part no. 10.90.72.00) to top retainer and at the centre of the valve to be removed. • Tighten the tool screw until it starts pulling, then tap with a mallet on tool head (working on top retainer) so to detach the two valve cotters (1) from top plate (2).

  • Page 57: Checking The Components

    ENGINE Engine V1100 3.5.3. CHECKING THE COMPONENTS HEADS Ensure that: • Surfaces mating with cover and cylinder are not so scratched or damaged to compromise sealing. • Check that clearance between valve guide hole and valve stem is within recommended limit.
  • Page 58 ENGINE Engine V1100 VALVE SEATS Grind the valve seats with a cutter. Seat slant angle is 45°± 5’. After milling, grind to ensure correct coupling and perfect sealing between valve head and ring nut. INTAKE VALVE SEAT DETAIL VIEW EXHAUST VALVE SEAT DETAIL VIEW...

  • Page 59: Reassembling The Heads

    ENGINE Engine V1100 3.5.4. REASSEMBLING THE HEADS NOTE The following procedure applies to both cylinder heads. • Refit valve (6) inside the head. • Fit the bottom retainer (5) and the shims. • Refit the external spring (4). • Refit the internal spring (3).
  • Page 60 ENGINE Engine V1100 • Set 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. 3 - 33...
  • Page 61 ENGINE 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 plug. 3 - 34...
  • Page 62 ENGINE Engine V1100 • Connect the line 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 left cylinder to TDC in combustion stage (valves closed).
  • Page 63 ENGINE Engine V1100 • Install the external spark plug. • Change the gasket and install the head cover, see (REMOVING THE HEAD COVERS). 3 - 36...

  • Page 64: Cylinders And Pistons

    ENGINE Engine V1100 3.6. CYLINDERS AND PISTONS 3.6.1. REMOVAL, CHECK AND INSTALLATION 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 piston.
  • Page 65 ENGINE Engine V1100 • Remove the gudgeon pin. • Mark the piston crown on exhaust side to ensure correct reassembly. • Remove the piston. CHECK Checking cylinder wear: Cylinder diameter is to be measured at three heights, turning the dial gauge by 90°.
  • Page 66 ENGINE Engine V1100 Checking the pistons During overhaul, remove scaling from piston crown and ring grooves; check clearance between cylinder and piston on diameter (refer to the relevant class); if it exceeds reference value, change cylinders and pistons. The pistons of an engine should be balanced; a difference in weight is allowed up to 1.5 grams (0.0033 lb).
  • Page 67 ENGINE Engine V1100 INSTALLATION NOTE The following procedure applies to both cylinder heads. • Fit the piston NOTE Check piston correct position referring to the reference marks on the piston crown. Never match pistons to cylinders of different classes. •...
  • Page 68 ENGINE Engine V1100 • Remove the piston ring tool (part no. 05.92.80.30) and position the cylinder. • Fit the gasket at cylinder base. • Install the head, see (REFITTING THE HEADS). 3 - 41...

  • Page 69: Flywheel

    ENGINE Engine V1100 3.7. FLYWHEEL 3.7.1. REMOVAL, CHECK AND REASSEMBLY REMOVAL • Remove the clutch, see (REMOVING THE 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.
  • Page 70 ENGINE Engine V1100 REASSEMBLY • Perform the removal procedure in reversed order. NOTE Respect flywheel position reference marks. WARNING Renew the screws upon reassembly since they undergo important stress and load. 3 - 43...

  • Page 71: Crankshaft And Connecting Rods

    ENGINE Engine V1100 3.8. CRANKSHAFT AND CONNECTING RODS 3.8.1. REMOVAL • Remove the heads, see (REMOVING THE HEADS). • Remove the cylinders and pistons, see (REMOVAL, CHECK AND INSTALLATION). • Remove the clutch, see (REMOVING THE CLUTCH). • Remove the flywheel, see (REMOVAL, CHECK AND REASSEMBLY).
  • Page 72 ENGINE 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. 3 - 45...

  • Page 73: Check

    ENGINE Engine V1100 3.8.2. CHECK WARNING During this operation flammable vapours are generated and metal particles might be ejected at high speed, it is therefore recommended to avoid bare flames or sparks in the work place; the operator should wear suitable goggles.
  • Page 74 ENGINE Engine V1100 Con-rod bearings thickness Bearings for crank pin ø undersized by mm (inch) STANDARD BEARING (PRODUCTION) mm (inch) 0.254 (0.00999) 0.508 (0.01999) 0.762 (0.02999) 1.662 (0.06543) 1.789 (0.07043) 1.916 (0.07543) From 1.535 (0.06043) to 1.544 (0.06079) 1.671 (0.06578) 0.798 (0.07079)
  • Page 75 ENGINE Engine V1100 WARNING When grinding the crankshaft pins/journals refer to the shoulder radius value that is: 2.0 ÷ 2.5 mm (0.079 ÷ 0.984 in) for the crank pin, 3.0 ÷ 3.2 mm (0.118 ÷ 1.260 in) for the journal on flywheel side, 1.5 ÷...

  • Page 76: Reassembly

    ENGINE Engine V1100 3.8.3. REASSEMBLY CONNECTING RODS Perform removal instructions in reverse order, consider the following warnings: • Renew the screws upon reassembly since they undergo important stress and load. • Assembly clearance between bearing and crank pin is minimum 0.022 mm (0.00087 inch), maximum 0.064 mm (0.00251 inch).

  • Page 77: Oil Sump

    ENGINE Engine V1100 3.9. OIL SUMP 3.9.1. REMOVAL, CHECK AND REASSEMBLY REMOVAL NOTE To remove the oil sump it is necessary to set a suitable collector under the sump to collect used oil and drain all oil from the sump.
  • Page 78 ENGINE Engine V1100 • Loosen and remove the four screws and remove the black oil sump. • Release and remove the two screws. • Release and remove the two screws. • Remove the mesh filter and collect the gasket. •...
  • Page 79 ENGINE Engine V1100 • Once these parts are removed, it is possible to gain access to 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.
  • Page 80 GEARBOX Engine V1100 GEARBOX 4 - 1...
  • Page 81 GEARBOX Engine V1100 SUMMARY 4.1. GEARBOX ................................ 3 4.1.1. DIAGRAM ..............................3 4.1.2. OPENING 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.

  • Page 82: Gearbox

    GEARBOX Engine V1100 4.1. GEARBOX 4.1.1. DIAGRAM 4 - 3...
  • Page 83 GEARBOX Engine V1100 Key: Ball bearing 38. Shaped washer Circlip 39. Sleeve Shim 40. Circlip 41. Idler gear Complete Desmodromic 42. Ball bearing Ball bearing 43. Gear Spring 44. Gear Spacer 45. Roller cage Circlip 46. Washer 10. Fifth wheel 47.

  • Page 84: Opening The Gearbox

    GEARBOX Engine V1100 4.1.2. OPENING THE GEARBOX • Remove the starter motor, see (REMOVING THE STARTER MOTOR). • Ensure that gearbox is in neutral. • Loosen and remove the screw and remove the gear shift lever. • Loosen and remove the plug.
  • Page 85 GEARBOX Engine V1100 • Release and remove the two screws. • Unscrew and remove the screw. • Remove the gearbox. • Set the gearbox on the suitable gearbox support (part no. 14.92.96.00) and in a vice. 4 - 6...
  • Page 86 GEARBOX Engine V1100 • Loosen and slide out the odometer fitment and collect the stop washer that stays inside the gearbox. • Slide out the cylinder and collect the O-ring and the washer. • Remove the thrust bearing and cap.
  • Page 87 GEARBOX Engine V1100 • Bend 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; collect the inner clutch body. • Using the suitable tool (part no. 05.91.25.30) open the gearbox.
  • Page 88 GEARBOX Engine V1100 • Open the gearbox, see (OPENING THE GEARBOX). • Release the spring. • Press on the selector to help removal of the complete transmission lever. • Loosen and remove the reference threaded pin. • Use elastic bands to tie the gearbox shafts and remove the unit.
  • Page 89 GEARBOX Engine V1100 • Remove the bearings from the gearbox. • Set 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.
  • Page 90 GEARBOX Engine V1100 • If necessary, change the bearings and remove the clutch shaft. 4 - 11...

  • Page 91: Disassembling The Primary Shaft

    GEARBOX Engine V1100 4.1.3. DISASSEMBLING THE 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, collect the roller cage.
  • Page 92 GEARBOX Engine V1100 • Remove the third and fourth speed gear. • Remove the circlip and collect the washer. • Remove the fifth speed gear and collect the roller cage. • Using a suitable heater, heat up the shaft and remove the transmission helical gear.

  • Page 93: Disassembling The Secondary Shaft

    GEARBOX Engine V1100 4.1.4. DISASSEMBLING 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 collect the roller cage and the washer.
  • Page 94 GEARBOX Engine V1100 • Remove the sixth speed gear. • Remove the circlip and collect the washer. • Remove the fourth speed gear and collect the roller cage. • Remove the third speed gear and collect the roller cage and the washer.
  • Page 95 GEARBOX Engine V1100 • Remove the circlip. • Remove the fifth speed gear. • Remove the circlip, the washer and slide out the first speed gear; collect the roller cage. • If necessary, remove the bearing. 4 - 16...

  • Page 96: Disassembling The Clutch Shaft

    GEARBOX Engine V1100 4.1.5. DISASSEMBLING THE CLUTCH SHAFT • Open the gearbox, see (OPENING THE GEARBOX). • If necessary, working on engine side, remove the cover seal (1) and bearing (2); collect the O-ring (3). • Working on gearbox side, remove the circlip (13) and the two split rings (12);...

  • Page 97: Check

    GEARBOX Engine V1100 4.1.6. CHECK CHECKING THE GEAR SHIFT FORKS NOTE The following procedure applies to all gear shift forks. Check the fork cam roller (1) and fork teeth (2) for damages, deformation and wear. Change the fork if needed.
  • Page 98 GEARBOX Engine V1100 CHECKING THE GEARBOX Using a gauge and a centring unit, measure primary shaft runout and change it if it does not comply with the specifications. Primary shaft limit runout: 0.08 mm (0.0031 in.) Using a gauge and a centring unit, measure secondary shaft runout and change it if it does not comply with the specifications.

  • Page 99: Reassembly

    GEARBOX Engine V1100 4.1.7. REASSEMBLY NOTE For reassembling the clutch shaft, the secondary shaft, the primary shaft and for closing the gearbox, follow the removal instructions in reverse order. Remember to change all seals, circlips and snap rings removed. 4 - 20...

  • Page 100: Clutch

    GEARBOX Engine V1100 4.2. CLUTCH 4.2.1. REMOVING THE CLUTCH • Remove the gearbox unit, see (REMOVING THE GEARBOX). • Fit locking tool (part no. 12.91.18.01) to the flywheel and tool (part no. 30.90.65.10) to compress clutch springs. • Loosen and remove the eight screws securing the flywheel gear wheel.
  • Page 101 GEARBOX Engine V1100 From inside the flywheel, remove: • the clutch plate; • the intermediate plate; • the second clutch plate; • the pusher plate nut; 4 - 22...
  • Page 102 GEARBOX Engine V1100 • the pusher plate together with springs. 4 - 23...

  • Page 103: Checking The Components

    GEARBOX Engine V1100 4.2.2. CHECKING THE COMPONENTS Clutch springs Check that the springs are not yielded or deformed: • Springs compressed to 22 mm (0.8661 inch) should give a load of 11.25 ÷ 11.70 Kg. (24.80 ÷ 25.79 lb); •...

  • Page 104: Refitting The Clutch

    GEARBOX 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.
  • Page 105 GEARBOX 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. 4 - 26...
  • Page 106 GEARBOX Engine V1100 • Position the gear wheel aligning 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 the clutch springs.
  • Page 107 GEARBOX Engine V1100 4 - 28...
  • 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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