MOTO GUZZI Engine V1100 Workshop Manual
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MOTO GUZZI Engine V1100 Workshop Manual

MOTO GUZZI Engine V1100 Workshop Manual

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Summary of Contents for MOTO GUZZI Engine V1100

  • Page 1 Engine V1100 workshopmanual...

  • Page 2: Introduction

    INTRODUCTION Engine V1100 INTRODUCTION 0 - 1...
  • Page 3 INTRODUCTION 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 0 - 2...

  • Page 4: Foreword

    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 ≥ = greater 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 GENERAL INFORMATION Engine V1100 TABLE OF CONTENTS 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.

  • 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. For quick reference, see the summary of sections.

  • 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. When you find this symbol on the vehicle or in the manual, be careful of the potential risk of personal injury. Disregarding the instructions identified by this symbol may compromise the safety of the user, the motorcycle and third parties.

  • Page 12: General Rules

    GENERAL INFORMATION Engine V1100 1.2. GENERAL RULES 1.2.1. BASIC SAFETY RULES CARBON MONOXIDE When an operation must be performed with the engine running, position the motorcycle outdoors in a well-ventilated area. Never run the engine in an enclosed place. Use an exhaust emission extraction system when working indoors.

  • Page 13: Dangerous Elements

    GENERAL INFORMATION Engine V1100 HYDROGEN GAS AND BATTERY ELECTROLYTE DANGER The battery electrolyte is a toxic, caustic substance containing sulfuric acid and thus able to cause severe burns case contact. Wear close-fitting gloves protective clothing when handling this fluid. If any battery fluid gets on your skin, rinse the affected area with abundant fresh water.
  • Page 14 NOTE All bearings must run freely with no hardness or noise. Replace any bearings that do not meet these requirements. Use ORIGINAL Moto Guzzi spare parts only. Use the specified lubricants and consumables. Where possible, lubricate a part before assembly.
  • Page 15 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. Refueling and maintenance operations should be carried out in a well-ventilated area, with the engine off.
  • Page 16 GENERAL INFORMATION Engine V1100 BRAKE FLUID NOTE This vehicle is fitted with front and rear disc brakes. Each brake system is operated by an independent hydraulic circuit. The information provided below applies to both brake systems. DANGER Do not drive the vehicle if the brakes are worn or not operating correctly. The brakes are the vehicle’s most important safety component and using the vehicle with the brakes in less than perfect operating condition comprises a high probability of traffic accident, which can result in serious injury or death.
  • Page 17 GENERAL INFORMATION Engine V1100 TIRES WARNING An over inflated tire results in a hard, uncomfortable and less secure ride. Over inflation also affects grip, especially on curves and wet surfaces. An under inflated tire (insufficient pressure) can slip on the wheel rim, resulting in loss of control.

  • Page 18: Running-In

    GENERAL INFORMATION Engine V1100 1.4. RUNNING-IN 1.4.1. RUNNING-IN Proper engine running in is essential to preserving engine life and performance over time. Twisty roads and gradients are ideal to break in engine, suspension and brakes effectively. Varying speed frequently is also recommended.

  • 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 vehicle registration. NOTE Altering the vehicle's identification numbers is punishable by law with heavy fines and penalties. Altering the frame number voids the warranty.

  • Page 20: Technical Information

    TECHNICAL INFORMATION Engine V1100 TECHNICAL INFORMATION 2 - 1...
  • Page 21 TECHNICAL INFORMATION 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 2 - 2...

  • Page 22: Technical Data

    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 cm (65 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 TECHNICAL INFORMATION Engine V1100 2.1.3. TIGHTENING TORQUES 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 damage that might be avoided if the special tools are used. Following are the special tools designed specifically 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 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 cover on sump and filter 01.92.91.00...
  • Page 28 ENGINE Engine V1100 ENGINE 3 - 1...
  • Page 29 ENGINE Engine V1100 TABLE OF CONTENTS 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.
  • Page 30 ENGINE 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. 3 - 3...
  • Page 31 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. • Loosen the two clamps securing 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 ENGINE 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. 3 - 6...

  • Page 34: Adjuster

    ENGINE Engine V1100 • Loosen and remove the two screws. • Loosen the nut and set aside the screw. • Loosen the screw. • Loosen the nut and release the adjuster, so that the generator is free to slide down.
  • Page 35 ENGINE Engine V1100 • 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.
  • Page 36 ENGINE Engine V1100 • Remove the generator subframe. • Remove the seal, if necessary. 3 - 9...
  • Page 37 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 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 set aside the washer. • Loosen and remove the nut and set aside the washer. • Slide out the chain tensioner and set aside the spring.
  • Page 43 ENGINE 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 side.
  • Page 44 ENGINE Engine 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 instructions in reverse order.
  • Page 45 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.) Exhaust valve clearance 0.15 mm (0.0059 in.)
  • Page 46 ENGINE Engine V1100 3.3.3. TIMING To check the timing proceed as follows: • Set clearance between the rocker arms and valves to 1.5 mm (0.059 in); • Fit the degree wheel hub (part no. 65.92.84.00) with the degree wheel (part no. 19.92.96.00) in crankshaft groove;...
  • Page 47 ENGINE Engine V1100 • Check the timing, with reference to the timing diagram, considering that: A – intake starts before TDC B – exhaust ends after TDC C – exhaust starts before BDC D - intake ends after BDC •...
  • Page 48 ENGINE Engine V1100 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 against the pick-up ring.
  • Page 49 ENGINE Engine V1100 • Measure the clearance between the plate 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, fit the sensor and tighten the screws to the specified torque.
  • Page 50 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 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 set aside the bushings. • Remove the head cover and set aside the gasket.
  • Page 52 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 the left cylinder to TDC in combustion stage (valves closed).
  • Page 53 ENGINE Engine 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 set aside the washer.
  • Page 54 ENGINE Engine V1100 • 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 the internal spark plug.
  • Page 55 ENGINE 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 gasket. 3 - 28...
  • Page 56 ENGINE Engine V1100 • Fit the special tool (part no. 10.90.72.00) on top retainer and at the center of the valve to be removed. • Tighten the tool screw until it starts pulling, then tap the tool head (working on top retainer) with a mallet so as to detach the two valve cotters (1) from top plate (2).
  • Page 57 ENGINE Engine V1100 3.5.3. CHECKING THE COMPONENTS HEADS Make sure that: • Surfaces in contact with the cover and cylinder are not scratched or damaged to the point where they compromise sealing. • Check that clearance between valve guide holes and valve stems is within the 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 the valve head and the ring nut. INTAKE VALVE SEAT DETAIL VIEW...
  • Page 59 ENGINE Engine V1100 3.5.4. REASSEMBLING THE HEADS NOTE The following procedure applies to both cylinder heads. • Refit the valve (6) inside the head. • Fit the bottom retainer (5) and the shims. • Refit the external spring (4). •...
  • Page 60 ENGINE 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. 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 the 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 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 the 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 the piston crown and ring grooves; check clearance between the cylinder and piston on the diameter (refer to the relevant class); if it exceeds the reference value, replace the cylinders and pistons.
  • Page 67 ENGINE Engine V1100 INSTALLATION NOTE The following procedure applies to both cylinder heads. • Fit the piston NOTE Check the correct piston 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 the cylinder base. • Install the head, see REFITTING THE HEADS. 3 - 41...
  • Page 69 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 Replace the screws upon reassembly as they are subject to considerable stress and load. 3 - 43...
  • Page 71 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 ENGINE Engine V1100 3.8.2. CHECK WARNING During this operation flammable vapors are generated and metal particles might be ejected at high speed. We therefore recommend 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 (in) STANDARD BEARING (PRODUCTION) mm (in) 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 - 1.8 mm (0.059 - 0.071 in) for...
  • Page 76 ENGINE Engine V1100 3.8.3. REASSEMBLY CONNECTING RODS Perform removal instructions in reverse order, consider the following warnings: • Replace the screws upon reassembly as they are subject to considerable stress and load. • Assembly clearance between the bearing and crank pin is minimum 0.022 mm (0.00087 in), maximum...
  • Page 77 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 place a suitable container 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. • Loosen and remove the two screws. • Loosen and remove the two screws. • Remove the mesh filter and set aside the gasket.
  • Page 79 ENGINE Engine V1100 • Once these parts are removed, it is possible to access 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 TABLE OF CONTENT 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 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. Idle 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 GEARBOX Engine V1100 4.1.2. OPENING THE GEARBOX • Remove the starter motor, see REMOVING THE STARTER MOTOR. • Make sure that the gearbox is in neutral. • Loosen and remove the screw and remove the gear shift lever. • Loosen and remove the plug.
  • Page 85 GEARBOX 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. 4 - 6...
  • Page 86 GEARBOX Engine V1100 • Loosen and slide out the 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.
  • Page 87 GEARBOX Engine V1100 • Bend the 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 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 remove 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. • 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.
  • Page 90 GEARBOX Engine V1100 • If necessary, replace the bearings and remove the clutch shaft. 4 - 11...
  • Page 91 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, set aside the roller cage.
  • Page 92 GEARBOX Engine V1100 • 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 transmission helical gear.
  • Page 93 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 set aside the roller cage and the washer.
  • Page 94 GEARBOX Engine 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 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; set aside the roller cage. • If necessary, remove the bearing. 4 - 16...
  • Page 96 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); set aside the O-ring (3). • Working on the gearbox side, remove the circlip (13) and the two split rings (12);...
  • Page 97 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 damage, deformation and wear. Replace the fork if necessary.
  • Page 98 GEARBOX Engine V1100 CHECKING THE GEARBOX Using a gauge and a centering unit, measure primary shaft runout and replace it if it does not comply with the specifications. Primary shaft limit runout: 0.08 mm (0.0031 in) Using a gauge and a centering unit, measure secondary shaft runout and replace it if it does not comply with the specifications.
  • Page 99 GEARBOX Engine V1100 4.1.7. REASSEMBLY 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 and snap rings removed with new ones.
  • Page 100 GEARBOX Engine V1100 4.2. CLUTCH 4.2.1. REMOVING THE CLUTCH • 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 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 GEARBOX Engine V1100 4.2.2. CHECKING THE COMPONENTS Clutch springs Check the springs for yielding and deformation: • Springs compressed to 22 mm (0.8661 in) should give a load of 11.25 - 11.70 kg (24.80 - 25.79 lb); • Springs compressed to 20 mm (0.7874 in) should have a load of 14.75 - 15.30 kg (32.52 - 33.73 lb);...
  • Page 104 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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