MOTO GUZZI V85 E4 Manual
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MOTO GUZZI V85 E4 Manual

MOTO GUZZI V85 E4 Manual

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MANUALE STAZIONE DI SERVIZIO
2Q000383
Engine V85 E4

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Summary of Contents for MOTO GUZZI V85 E4

  • Page 1 MANUALE STAZIONE DI SERVIZIO 2Q000383 Engine V85 E4...
  • Page 2 The reliability of the vehicle also depends on its mechanical conditions. Checking the vehicle before riding it, its regular maintenance and the use of original Moto Guzzi spare parts only are essential factors! For information on the nearest Official Dealer and/or Service Centre consult our website: www.motoguzzi.com...
  • Page 3 Le principali modifiche tecniche e modifiche alle procedure per le riparazioni del veicolo vengono comunicate a tutti i Punti Vendita Moto Guzzi e alle Filiali nel Mondo. Tali modifiche verranno apportate, nelle edizioni successive di questo manuale. Nel caso di necessità o dubbi sulle procedure di riparazione e di controllo, interpellare il REPARTO ASSISTENZA Moto Guzzi, il quale sarà...
  • Page 4 Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee...

  • Page 5: Index Of Topics

    INDEX OF TOPICS CHAR HARACTERISTICS S-TOOLS PECIAL TOOLS NGINE...
  • Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 7: Tightening Torques

    Engine V85 E4 Characteristics Tightening Torques If the following tables do not expressly indicate the tightening torque values, refer to the table with the generic torque values indicated below. ENERAL TIGHTENING TORQUES Metric tightening torque: TE - TEFL - SHC - TBEI 3 Nm (2.21...
  • Page 8 INDEX OF TOPICS S-TOOLS PECIAL TOOLS...
  • Page 9 Engine V85 E4 Special tools SPECIAL TOOLS Stores code Description 020997Y Engine mounting 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 ring compressor...
  • Page 10 Engine V85 E4 Special tools Stores code Description 020713Y Flywheel extractor 020976Y Clutch control dust guard mounting punch 021020Y Clutch housing oil seal mounting punch 021001Y Clutch lock 021002Y Clutch centring S-TOOLS - 10...
  • Page 11 INDEX OF TOPICS NGINE...
  • Page 12 Engine V85 E4 Engine Gearbox Diagram key: 1. Thrust washer 2. 2nd speed gear on main shaft 3. Circlip 4. Thrust washer 5. 6th speed gear on main shaft 6. Floating bushing 7. Main shaft thrust washer 8. 3rd and 4th speed sliding gear on main shaft 9.

  • Page 13: Removing The Gearbox

    Engine V85 E4 Engine 17.Floating bushing 18.Thrust washer 19.Circlip for the shaft 20.6th speed gear on transmission shaft 21.Circlip for the shaft 22.Thrust washer 23.3rd speed gear on transmission shaft 24.Floating bushing 25.4th speed gear on transmission shaft 26.Floating bushing 27.Thrust washer...
  • Page 14 Engine V85 E4 Engine • Remove the fixing screw (2) of the gearbox, placed 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.
  • Page 15 Engine V85 E4 Engine • Remove the external body (1), the thrust bearing (2) and two related slid- ing washers (3) and the external body (4). • Remove the pusher plate • Remove the gearbox cover with a few mallet strokes •...
  • Page 16 Engine V85 E4 Engine • The bearings from the gearbox crank- cases can be removed using generic extractors. • Heat the primary shaft bearing area on the base of the gearbox crankcase and the secondary shaft area on the gear- box crankcase cover very well with a hair dryer.

  • Page 17: Remove The Shim

    Engine V85 E4 Engine • Remove the gear selector shaft, the desmodromic shaft and the forks 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) •...
  • Page 18 Engine V85 E4 Engine • Remove the spacer (4) • Remove the gear of the 6th gear (5) • Remove the bushing (6) • Remove the spacer (7) ENG - 18...

  • Page 19: Remove The Gear Of The 5Th

    Engine V85 E4 Engine • Remove 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)
  • Page 20 Engine V85 E4 Engine • Remove the bushing (12) • Remove the washer (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) •...
  • Page 21 Engine V85 E4 Engine • Remove the bushing (3) • Remove the shim washer (4) • Remove the seeger ring (5) • Remove the gear of the 5th gear (6) ENG - 21...

  • Page 22: Remove The Seeger

    Engine V85 E4 Engine • Remove the seeger ring (7) • Remove the shim washer (8) • Remove the gear of the 4th gear (9) • Remove the bushing (10) ENG - 22...
  • Page 23 Engine V85 E4 Engine • Remove the gear of the 3rd gear (11) • Remove the bushing (12) • Remove the shim washer (13) • Remove the seeger ring (14) ENG - 23...
  • Page 24 Engine V85 E4 Engine • 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) ENG - 24...
  • Page 25 Engine V85 E4 Engine • Remove the bushing (19) Desmodromic 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. •...

  • Page 26: Disassembling The Clutch Shaft

    Engine V85 E4 Engine • Remove the lower fork No.3 (4) • Remove the primary and secondary shaft, as well as the intermediate fok No. 2 Disassembling the clutch shaft • To remove the clutch shaft it is neces- sary to remove first all gearbox com-...
  • Page 27 Engine V85 E4 Engine • Remove the oil seal CAUTION IN CASE OF OIL SEAL REPLACEMENT, USE THE SUITA- BLE PUNCH UNTIL IT REACHES THE CRANKCASE Specific tooling 021020Y Clutch housing oil seal mounting punch Controllo alberi Check transmission gears for signs of pitting and wear and replace damaged gears if necessary.

  • Page 28: Assembling The Gearbox

    Engine V85 E4 Engine Checking the forks Check that the forks have the work surface well smooth and not worn, so to lose its quenching characteristics and that the nibs that are working in the drum grooves are not too worn, otherwise replace the forks.
  • Page 29 Engine V85 E4 Engine • After inserting all the internal compo- nents, apply a layer of threebond on the junction surface of the two crank- casings. • Position the gearbox cover and man- ually tighten the gearbox fixing screw on the cardan side.

  • Page 30: Gear Selector

    Engine V85 E4 Engine • After inserting the two half-cones (1) on the thrust plate (2), insert it on the clutch shaft working from the cardan side and paying attention to the orien- tation, as the machining must push on the cap once the reassembling of the gearbox on the engine is complete.

  • Page 31: Remove The

    Engine V85 E4 Engine • Remove the washer (3) • Remove the seeger ring (4) • Remove the seeger ring (5) • Remove the washer (6) ENG - 31...
  • Page 32 Engine V85 E4 Engine • Remove the bushing (7) • Remove the selector 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...
  • Page 33 Engine V85 E4 Engine • Remove the index lever (11) • Remove the selector return spring (13) Generatore Rimozione sensore giri • Undo and remove the fixing screw of the sensor • Remove the timing system cover sen- ENG - 33...

  • Page 34: Generator Removal

    Engine V85 E4 Engine 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...
  • Page 35 Engine V85 E4 Engine • Using one of the fixing screws of the gearbox assembly, secure the specific tool. • Place the tool (1) on the rotor, tighten the threaded pin (2) of the tool and pro- ceed with the rotor removal...

  • Page 36: Generator Installation

    Engine V85 E4 Engine • Extract the oil seal STATOR REMOVAL • Remove the stator wiring harness lock plate • Removing the three stator fixing screws makes it possible to disconnect Generator Installation • During refitting of the flywheel cover it...

  • Page 37: Removing The Starter Motor

    Engine V85 E4 Engine • Check that plentiful threebond leaks out and covers all space between the seat on the cover and the cable grom- met. Apply another layer of threebond over the cable grommet. • Refit a new gasket.

  • Page 38: Disassembling The Clutch

    Engine V85 E4 Engine Clutch side Disassembling the clutch • Remove the clutch cover. • Partially unscrew the two fixing screws of the clutch plate, as indicated, to al- low the correct positioning of the spe- cific clutch lock tool.
  • Page 39 Engine V85 E4 Engine • Remove the clutch disc. • Remove the retainer ring • Remove the thrust plate • Remove the 6 fixing screws of the lock- ing plate ENG - 39...

  • Page 40: Checking The Clutch Plates

    Engine V85 E4 Engine • Remove the reinforcement flange of the clutch thrust plate • Remove the clutch lock complete • 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...

  • Page 41: Assembling The Clutch

    Engine V85 E4 Engine Starting sprocket Check that the supporting surface with the driven plate is perfectly smooth and even. Also check that the toothing where the starter mo- tor pinion works is not chipped or scratched; oth- erwise, replace it.
  • Page 42 Engine V85 E4 Engine • Insert the 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...
  • Page 43 Engine V85 E4 Engine • Place the starter sprocket and screw the fixing screws by hand • Using the special tool for the centring of the clutch plate Specific tooling 021002Y Clutch centring • Insert the six fastening screws at the recommended torque.
  • Page 44 Engine V85 E4 Engine RANKCASE HOLE DIAMETER Specification Desc./Quantity Class 1 Bushing seat diameter: 43.657-43.663 mm (1.7188-1.7190 in) Class 2 Bushing seat diameter: 43.664-43.670 mm (1.7191-1.7193 in) Class 3 Bushing seat diameter: 47.130-47.136 mm (1.8555-1.8557 in) Class 4 Bushing seat diameter: 47.137-47.142 mm (1.8558-1.8560 in) Four different crankcase classes are available: •...

  • Page 45: Removing The Head Cover

    Engine V85 E4 Engine AIN CRANKSHAFT JOURNAL DIAMETER 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: 43.016-43.023 mm (1.6935-1.6937 in) Four different crankshaft classes are available: •...

  • Page 46: Removing The Cylinder Head

    Engine V85 E4 Engine THE OPERATIONS FOR THE REMOVAL OF THE HEAD COVER ARE THE SAME FOR BOTH SIDES • Remove the spark plug cover • Disconnect the spark plug tube • Remove the blow-by pipe • Undo the three fixing screws of the head cover and remove the gasket •...
  • Page 47 Engine V85 E4 Engine • Remove the head cover • Unscrew the spark plug CAUTION THE INTAKE VALVE IS CHARACTERIZED BY THE PRES- ENCE OF A CALIBRATED PAD, THEREFORE PAY PAR- TICULAR ATTENTION TO RECOVER IT DURING DISAS- SEMBLY. •...
  • Page 48 Engine V85 E4 Engine • Remove the rocker pin • Remove the rocker, being careful to re- cover the Belleville spring NOTE REPEAT THE SAME PROCEDURE TO REMOVE THE OTH- ER ROCKER • Remove the rocker rods • Unscrew and remove the compensa-...
  • Page 49 Engine V85 E4 Engine • Undo and remove the fastening nuts of the cam tower • Remove the cam tower • Remove 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 •...
  • Page 50 Engine V85 E4 Engine • Remove the cylinder head gasket • Undo and remove the engine oil pres- sure sensor • Undo and remove the secondary air valve cover • Remove the secondary air valve • check and if necessary replace the ex-...

  • Page 51: Cylinder Head

    Engine V85 E4 Engine • Remove the internal filter paying atten- tion to the direction during refitting Cylinder head Removing the valves • Place the special tool on the upper cap of the valve to be removed and at the centre of the head of the valve.
  • Page 52 Engine V85 E4 Engine • Remove the spring and replace it if it is out of the wear limit. • Remove the valve from the head • Remove the gasket of the valve guide VALVE GUIDES MUST BE REPLACED WHEN THEY ARE...

  • Page 53: Checking The Rocker Arms

    Engine V85 E4 Engine Checking the rocker arms • Check that the bolt surface that con- tacts the rockers is not exceedingly worn. • Check the rocker to valve and rocker to rod contact surfaces. Valve check If the below shown values are out of the limits of the component wear, replace it...

  • Page 54: Inspecting The Springs And Half-Cones

    Engine V85 E4 Engine Inspecting the springs and half-cones • Check that the upper spring caps and the half-cones show no signs of abnor- mal wear. • Check the unloaded spring length. Characteristic Spring free length (WEAR LIMIT) 45.9 mm (1.81 in) Adjusting valve clearance •...
  • Page 55 Engine V85 E4 Engine • Loosen the lock nut, adjust the clear- ance by acting on the adjuster until reaching the prescribed values • Tighten the lock nut Timing Rimozione ruota fonica • Remove the timing system cover. • Remove the rotor.

  • Page 56: Removing The Chain Tensioner

    Engine V85 E4 Engine Removing the chain tensioner • Remove the timing system cover • Remove the rotor • Remove the chain tensioner fixing screw recovering the washer • Remove the chain tensioner Chain removal • Remove the timing system cover, the rotor and the tone wheel.

  • Page 57: Removing The Camshaft

    Engine V85 E4 Engine • Remove the timing chain, removing the camshaft gear and the oil pump gear at the same time Rimozione piattello blow-by • Remove the timing system cover, the rotor and tone wheel complete with spacer •...

  • Page 58: Installing The Camshaft

    Engine V85 E4 Engine • Remove the camshaft extracting it from the crankcase. Installing the camshaft • Insert the camshaft into the crankcase. • Place the two fixing screws and tighten them to the prescribed torque. Installazione piattello blow-by •...

  • Page 59: Cam Timing

    Engine V85 E4 Engine Installazione catena • For the installation of the timing chain, it is necessary to carry out the "Timing" procedure, therefore consult the specific chapter. See also Timing Installing the phonic wheel • Fit the tone wheel checking the correct...
  • Page 60 Engine V85 E4 Engine • Having positioned the blow-by cap, fit the timing chain together with timing system gear and oil pump gear. WARNING PRIOR TO POSITIONING THE TIMING CHAIN WITH GEAR, ALIGN AS MUCH AS POSSIBLE THE MILLING PRESENT...
  • Page 61 Engine V85 E4 Engine • Fit the knurled washer and after plac- ing the nut, tighten it to the prescribed torque • Position the three fixing screws of the timing gear and tighten to the prescri- bed torque. • Position the tone wheel and after in- serting the fixing screw with washer, tighten to the prescribed torque.

  • Page 62: Removing The Cylinder

    Engine V85 E4 Engine Removing the cylinder • Remove the nut with relevant washer of the cylinder to the crankcase • Slide off the cylinder from the stud bolts. • Remove the gasket from the stud bolts Disassembling the piston •...

  • Page 63: Checking The Cylinder

    Engine V85 E4 Engine • Before removing the pin, check the mounting clearance between pin and piston. Replace it if the value is out of the limits • Slide off the pin Characteristic Mounting clearance between piston and pin 0.01 mm (0.0004 in) •...

  • Page 64: Checking The Piston

    Engine V85 E4 Engine Type Allowed diameter Assembly clearance between piston and cylinder 84.007-84.014 mm (3.3074-3.3076 in) 0.040-0.054 mm (0.0016-0.0021 in) 84.014-84.021 mm (3.3076-3.3079 in) 0.040-0.054 mm (0.0016-0.0021 in) 84.021-84.028 mm (3.3079-3.3082 in) 0.040-0.054 mm (0.0016-0.0021 in) Checking the piston •...

  • Page 65: Inspecting The Piston Rings

    Engine V85 E4 Engine Inspecting the piston rings • Clean off any carbon deposits from the grooves in the piston rings and from the rings themselves. • Measure the piston ring side clearance and replace the piston and the piston rings all together if not complying with specifications.

  • Page 66: Installing The Cylinder

    Engine V85 E4 Engine • Insert the pin • Insert the retainer ring Installing the cylinder • Check that the piston ring end gaps are approximately 120 degrees from each other. • Fit a new gasket • Place the appropriate ring clamp on the piston •...
  • Page 67 Engine V85 E4 Engine • After fitting the cylinder it is necessary to check the piston projection for cor- rect head gasket selection. • Fit a dial gauge on the specific tool and set it to zero on a horizontal plane.

  • Page 68: Installing The Cylinder Head

    Engine V85 E4 Engine Installing the cylinder head • Insert the flame trap of the secondary air valve • Insert the reed valve • Fit the cover of the secondary air valve and tighten the screws to the prescri- bed torque •...
  • Page 69 Engine V85 E4 Engine • Place the gasket • Place engine 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 •...
  • Page 70 Engine V85 E4 Engine • Following a cross order "A-C-B-D" screw the fixing nuts of the cam tower to the prescribed torque • Insert and tighten the compensation nut of the cam tower to the prescribed torque • Insert the rocker rods...
  • Page 71 Engine V85 E4 Engine • Place the rocker in its seat by inserting the Belleville spring at the same time • Using the rocker shim centring pin, align the rocker and the Belleville spring with the pin seat for easy insertion...

  • Page 72: Crankcase - Crankshaft

    Engine V85 E4 Engine • 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 the seats of the fixing screws •...

  • Page 73: Splitting The Crankcase Halves

    Engine V85 E4 Engine 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 the four long nuts from the inside of the crankcase.

  • Page 74: Removing The Crankshaft

    Engine V85 E4 Engine Removing the crankshaft • Remove the crankshaft 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 the connecting rod •...

  • Page 75: Checking The Connecting Rod

    Engine V85 E4 Engine THE CRANKSHAFT IS NITRIDED AND CANNOT BE GROUND; IF WORN, TAPERED OR DEEPLY SCORED, THE CRANKSHAFT MUST BE REPLACED RANKSHAFT CHECK IMIT VALUES Specification Desc./Quantity Main journal diameter on timing system side (WEAR LIMIT 40.004 mm (1.5750 in)
  • Page 76 Engine V85 E4 Engine • Connecting rods are available in two selections (A/blue - B/white, identified respectively by a white or blue dot in the zone indicated by the letter X in the drawing). These must be assembled correctly with the crankshaft, which is categorised into two different selections in relation to crankpin size (A/blue - B/white, identified respectively by a white or blue dot in the zone indicated by the letter Y in the drawings), using the appropriate bushing.

  • Page 77: Refitting The Crankcase Halves

    Engine V85 E4 Engine • Before assembly, take careful note of the coupling classes. • Assemble the connecting rod on the crankpin in the crankcase, tightening the screws to the indicated torque. Refitting the crankcase halves • Insert the small ends timing system...
  • Page 78 Engine V85 E4 Engine • Insert the seal ring (after lubricating it) on the crankshaft and the assembly onto the engine crankcase making sure that the connecting rods locate correctly into their seats. • Smear the crankcases mating faces with the threebond •...
  • Page 79 Engine V85 E4 Engine • Remove the three fixing screws of the oil pump. • Remove the complete pump from the crankcase. • Remove the cover (1) from the pump (2). • Working on the oil pump gear side, re- move the external rotor (3).
  • Page 80 Engine V85 E4 Engine • Remove the internal rotor (4). • Remove the safety pin (5) from the pump drive shaft. • Working from the opposite side of the oil pump, extract the pump drive shaft (6) removing the internal rotor (7) and the external rotor (8).
  • Page 81 Engine V85 E4 Engine EXTERNAL 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 (0.4752 in) EXTERNAL ROTOR ( CRANKCASE SIDE)
  • Page 82 Engine V85 E4 Engine • Working from the front of the oil pump, insert the internal rotor retaining pin (4). • Insert the internal rotor (5) paying at- tention that the pin enters the machin- ing seat. • Insert the external rotor (6) paying at- tention to the punch mark that must be facing outwards.
  • Page 83 Engine V85 E4 Engine • Insert the three oil pump retaining screws and tighten them to the pre-de- fined tightening torque. Oil sump Removing the oil sump • Remove the engine oil filter fixing screw • Remove the engine oil filter •...
  • Page 84 Engine V85 E4 Engine • Remove the oil sump • Remove the gasket • Remove the rose pipe • Remove the cap and the relative cop- per gasket ENG - 84...
  • Page 85 Engine V85 E4 Engine • Remove the spring • Remove the overpressure valve Refitting the oil sump • Install the overpressure valve in the engine crankcase • Insert the spring and afterwards the cap provided with a new copper gas-...
  • Page 86 Engine V85 E4 Engine • Insert the rose pipe • Place the gasket and insert the oil sump cover • Insert and tighten the 14 fastening screws of the oil sump to the prescri- bed torque • Insert the engine oil filter together with...
  • Page 87 Engine V85 E4 Engine • Insert and tighten the locking screw of the engine oil filter to the prescribed torque ENG - 87...
  • Page 88 Chain: 56 Chain tensioner: 56 Clutch: 26, 27, 38, 40, 41 Crankcase: 72–74, 77 Crankshaft: 72, 74 Cylinder: 46, 51, 62, 63, 66, 68 Desmodromic drum: 27 Forks: 28 Head cover: 45, 72 Oil sump: 83, 85 Pistons: Primary shaft: 16 Secondary shaft: 20 Starter motor: 37...

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