MOTO GUZZI V85 TT Service Station Manual
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MOTO GUZZI V85 TT Service Station Manual

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SERVICE STATION MANUAL
2Q000400
V85 TT

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Summary of Contents for MOTO GUZZI V85 TT

  • Page 1 SERVICE STATION MANUAL 2Q000400 V85 TT...
  • 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 This manual provides the main information to carry out regular maintenance operations on your vehicle. This manual is intended to Moto Guzzi Dealers and their qualified mechanics; several concepts have been deliberately omitted as they are considered unnecessary. As it is not possible to include complete mechanical notions in this manual, users should have basic mechanical knowledge or minimum knowledge about the procedures involved when repairing scooters.
  • Page 5 INDEX OF TOPICS CHAR HARACTERISTICS S-TOOLS PECIAL TOOLS MAIN AINTENANCE ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE P SUPP OWER SUPPLY SUSP USPENSIONS CHAS HASSIS BRAK SYS RAKING SYSTEM BODYW ODYWORK PRE DE DELIVERY...
  • Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 7: Vehicle Identification

    V85 TT Characteristics Vehicle identification SERIAL NUMBER LOCATION These numbers are necessary for vehicle registration. NOTE ALTERING IDENTIFICATION NUMBERS MAY BE SERIOUSLY PUNISHABLE BY LAW. IN PAR- TICULAR, MODIFYING THE CHASSIS NUMBER IMMEDIATELY VOIDS THE WARRANTY. FRAME NUMBER The chassis number is stamped on the RH side of the headstock.
  • Page 8 V85 TT Characteristics Engine ENGINE Specification Desc./Quantity Type traverse-mounted twin-cylinder four-stroke V 90° Cylinder number Engine capacity 853 cm³ (52.05 cu.in) Bore / stroke 84x77 mm (3.31x3.03 in) Compression ratio 10.5 ± 0.5 : 1 Start-up Electric Engine idle speed...

  • Page 9: Indicator Lamps

    V85 TT Characteristics BULBS Specification Desc./Quantity High beam/low beam light Front daylight running lights Turn signal lights Rear daylight running light /stop light Dashboard lighting INDICATOR LAMPS Specification Desc./Quantity Gearbox in neutral High beam light Cruise control indicator light ABS indicator light...

  • Page 10: Wheels And Tyres

    V85 TT Characteristics Wheels and tyres TYRES Specification Desc./Quantity Front 110 / 80 R19 59V Inflation pressure 2.5 bar (250 kPa) (36.26 PSI) Rear 150 / 70 R17 69V Inflation pressure 2.8 bar (280 Kpa) (40.61 PSI) WARNING If knobbly tyres are used, we recommend reducing the in- flation pressure by 0.2 bar (20 Kpa) (2.90 PSI) at the front...
  • Page 11 INDEX OF TOPICS S-TOOLS PECIAL TOOLS...

  • Page 12: Special Tools

    V85 TT Special tools SPECIAL TOOLS Stores code Description 020998Y Pinion case wrench 020999Y Crown counter- lock ring wrench 021000Y Bevel gear pair support 021003Y Bevel gear oil seal punch 021005Y Punch seals on the bevel gear cover 020978Y Cardan secondary oil seal mounting...
  • Page 13 V85 TT Special tools Stores code Description GU19927900 Punch for pressing bearing inner ring on- to drilled pin 020376Y Sleeve for adaptors 020360Y 52 x 55-mm Adaptor 001467Y036 Bearing internal cup extractor 020966Y Steering adjustment socket 020888Y Preload tube clamp...
  • Page 14 V85 TT Special tools Stores code Description AP8140189 Tool for fitting oil seal for 43 mm (1.69 in) diameter hole AP8140146 Weight AP8140150 Bored shaft for bleeding plunger air AP8140149 Guard for assembly operations 020922Y Diagnostic tool 021017Y OBD cable for E5 vehicles...
  • Page 15 INDEX OF TOPICS MAIN AINTENANCE...

  • Page 16: Scheduled Maintenance Table

    V85 TT Maintenance Scheduled maintenance table NOTE CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VE- HICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS, OFF ROAD OR FOR TRACK USE. NOTE THE TIMES LISTED ON THE SCHEDULED MAINTENANCE TABLE INCLUDE TIME DEDICATED TO MANAGEMENT ACTIVITIES.

  • Page 17: Spark Plug

    V85 TT Maintenance ENSURE THAT THE VEHICLE CALIBRATION IS UP TO DATE AFTER UPDATING THE DIAGNOS- TIC TOOL. CAUTION AFTER THE PROVIDED MAINTENANCE PROGRAM IS INDICATED TO PROCEED WITH THE MAINTENANCE OF THE VEHICLE STARTING FROM THE SERVICE OF 10,000 Km OR 10...
  • Page 18 V85 TT Maintenance • Remove the cover (2). • Disconnect the spark plug cap (3) • Unscrew the spark plug (4) and re- move it Check • Keep the vehicle upright with both wheels on the ground. • Unscrew and remove the cap/dipstick (1).
  • Page 19 V85 TT Maintenance DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO THE FLUID. WHEN USING A FUNNEL OR ANY OTHER EL- EMENT, MAKE SURE IT IS PERFECTLY CLEAN. Replacement CAUTION THE UNIT MUST BE HOT WHEN THE OIL IS CHANGED AS UNDER SUCH CONDITIONS OIL IS FLUID AND THEREFORE EASY TO DRAIN.
  • Page 20 V85 TT Maintenance CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VE- HICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS, OFF ROAD OR FOR TRACK USE. THE OIL LEVEL MUST BE CHECKED WHEN THE ENGINE IS WARM.

  • Page 21: Engine Oil Filter

    V85 TT Maintenance • Unscrew and remove the filler plug (2) • Drain the oil into the container; allow several minutes for oil to drain out com- pletely. • Check and if necessary, replace the sealing washer of drainage plug (1).

  • Page 22: Air Filter

    V85 TT Maintenance • Remove the sump guard • Remove the manifold-terminal • Place a container of suitable capacity under the drain plug (1). • Unscrew and remove the drain plug (1). • Unscrew and remove the filler plug (2).

  • Page 23: Checking The Valve Clearance

    V85 TT Maintenance • Remove the filter box (2) • Unscrew and remove the screws (3) • Remove the cover (4). • Remove the filter element (5) DO NOT START THE ENGINE WITH THE AIR FILTER RE- MOVED. TO CLEAN THE FILTERING ELEMENT, USE A PRESSUR- ISED JET OF AIR, AIMING IT FROM THE INSIDE OUT- WARD.
  • Page 24 V85 TT Maintenance ADJUST WITH COLD ENGINE, WITH PISTON AT TOP DEAD CENTRE (TDC) IN COMPRESSION STROKE (VALVES CLOSED). • Initially check the valve clearance in the left cylinder, then remove the four fixing screws of the spark plug cover •...
  • Page 25 V85 TT Maintenance • Remove the head cover • Remove the spark plug ALSO REMOVE THE SPARK PLUG OF THE RIGHT CYLINDER TO BE ABLE TO MANUALLY ROTATE THE ENGINE, ENGAGE THE FIRST GEAR AND TURN THE REAR WHEEL •...
  • Page 26 V85 TT Maintenance • To perform the valve clearance of the right cylinder, it is necessary to bring the cylinder to the top dead centre, rotating the engine 270 degree Top-up FRONT BRAKE • Unscrew and remove the screws (1) •...
  • Page 27 V85 TT Maintenance REAR BRAKE • Undo and remove the screw (1) • Remove the bracket (2) • Unscrew and remove the cap (3) • Remove the gasket (4) RISK OF BRAKE FLUID SPILLING. DO NOT OPERATE THE BRAKE LEVER IF THE BRAKE FLUID RESERVOIR CAP IS LOOSE OR HAS BEEN REMOVED.

  • Page 28: Clutch System

    V85 TT Maintenance AVOID PROLONGED AIR EXPOSURE OF THE BRAKE FLUID. BRAKE FLUID IS HYGROSCOPIC AND ABSORBS MOISTURE WHEN IN CONTACT WITH AIR. LEAVE THE BRAKE FLUID RESER- VOIR OPEN ONLY FOR THE TIME NEEDED TO COMPLETE THE TOPPING-UP PROCEDURE.

  • Page 29: Headlight Adjustment

    Dealer to verify the proper operation of the clutch control. • If the adjuster stroke (5) is not sufficient to ensure the required clearance, con- tact an Authorised Moto Guzzi Dealer Headlight adjustment To carry out vertical adjustment of the light beam: •...
  • Page 30 V85 TT Maintenance • Slightly loosen the headlight fixing screw (2), and move the light beam manually to the desired position. • Once adjusted, tighten all the screws. After adjusting: NOTE CHECK THAT THE LIGHT BEAM VERTICAL DIRECTION IS CORRECT.
  • Page 31 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 32 V85 TT Electrical system Electrical system installation TABLE C - PRELIMINARY PHASE • Proceed as indicated in the figure TABLE D - PRELIMINARY PHASE 1. Plastic rivet (female) + plastic rivet (male) TABLE E - PRELIMINARY PHASE • Proceed as indicated in the figure TABLE F - PRELIMINARY PHASE 1.
  • Page 33 V85 TT Electrical system TABLE G - PRELIMINARY PHASE 1. Medium sized clamp TABLE H - PRELIMINARY PHASE • Arrange the wiring as illustrated in the figure TABLE I - PRELIMINARY PHASE • Arrange the wiring as illustrated in the...
  • Page 34 V85 TT Electrical system TABLE K - ABS SYSTEM PRE-MOUNTING 1. Large clamp (for canister filter) TABLE L - ABS SYSTEM PRE-MOUNTING 1. Large clamp (for canister filter) 2. Medium sized clamp TABLE M - ABS SYSTEM PRE-MOUNTING 1. Large clamp (for canister filter) 2.
  • Page 35 V85 TT Electrical system TABLE O - ASSEMBLY OF FRAME UNIT TO ENGINE 1. Temperature bulb connector TABLE P - ASSEMBLY OF FRAME UNIT TO ENGINE • Temperature bulbs connections car- ried out and objectified TABLE Q - ASSEMBLY OF FRAME UNIT TO ENGINE 1.
  • Page 36 V85 TT Electrical system TABLE S - ASSEMBLY OF FRAME UNIT TO ENGINE 1. Medium sized clamp 2. Large clamp TABLE T - ASSEMBLY OF FRAME UNIT TO EN- GINE 1. Fall sensor 2. Fuel pump Pass the fall sensor and fuel pump outputs under...
  • Page 37 V85 TT Electrical system TABLE A1 - VOLTAGE REGULATOR ASSEM- 1. Medium clamps (previously mounted) 2. Engine side flywheel cable 3. Regulator side flywheel cable 4. Horn cable TABLE A2 - VOLTAGE REGULATOR ASSEM- 1. Horn connectors 2. Horn TABLE A3 - VOLTAGE REGULATOR ASSEM- •...
  • Page 38 V85 TT Electrical system TABLE B - INSTRUMENT CLUSTER PRE-AS- SEMBLY AND ASSEMBLY ON THE BIKE 1. Air temperature sensor Assemble the external air temperature sensor as the first operation TABLE B1 - INSTRUMENT CLUSTER PRE-AS- SEMBLY AND ASSEMBLY ON THE BIKE 1.
  • Page 39 V85 TT Electrical system TABLE B4 - INSTRUMENT CLUSTER PRE-AS- SEMBLY AND ASSEMBLY ON THE BIKE 1. Small clamp Air temperature sensor fastenings TABLE B5 - INSTRUMENT CLUSTER PRE-AS- SEMBLY AND ASSEMBLY ON THE BIKE 1. Front right turn indicator connector 2.
  • Page 40 V85 TT Electrical system TABLE B8 - INSTRUMENT CLUSTER PRE-AS- SEMBLY AND ASSEMBLY ON THE BIKE 1. Instrument panel connector 2. Front headlamp connector Assemble the front light cluster and, after connect- ing it, fastened the connector to the frame support...
  • Page 41 V85 TT Electrical system TABLE D - HANDLEBAR 1. Rubber cable guide TABLE D1 - HANDLEBAR 1. Front stop switch TABLE D2 - HANDLEBAR 1. Right light switch TABLE D3 - HANDLEBAR 1. Left light switch ELE SYS - 41...
  • Page 42 V85 TT Electrical system TABLE D4 - HANDLEBAR 1. Clutch switch TABLE E - FRONT WHEEL SPEED SENSOR 1. Front speed sensor 2. Speed sensor fastening 3. Cable gland TABLE E1 - FRONT WHEEL SPEED SENSOR 1. Cable gland TABLE E2 - FRONT WHEEL SPEED SENSOR 1.
  • Page 43 V85 TT Electrical system TABLE E3 - FRONT WHEEL SPEED SENSOR 1. Clip TABLE E4 - FRONT WHEEL SPEED SENSOR 1. Speed sensor cable TABLE E5 - FRONT WHEEL SPEED SENSOR 1. Speed sensor cable Central part TABLE A - RIGHT INJECTOR CABLE ROUTING 1.
  • Page 44 V85 TT Electrical system TABLE A1 - LEFT INJECTOR CABLE ROUTING 1. Left injector connector TABLE B - FILTER BOX AND THROTTLE BODY CONNECTIONS 1. Throttle valve cable TABLE B1 - FILTER BOX AND THROTTLE BODY CONNECTIONS 1. Fastener clip...
  • Page 45 V85 TT Electrical system TABLE B3 - FILTER BOX AND THROTTLE BODY CONNECTIONS • Pull the following cable to the outside of the frame TABLE C - SIDE STAND SWITCH AND COR- RECT ASSEMBLY ON THE VEHICLE • Overall view of pre-assembly...
  • Page 46 V85 TT Electrical system TABLE C3 - SIDE STAND SWITCH AND COR- RECT ASSEMBLY ON THE VEHICLE 1. Fastener clip TABLE C4 - SIDE STAND SWITCH AND COR- RECT ASSEMBLY ON THE VEHICLE 1. Side stand cabling TABLE C5 - SIDE STAND SWITCH AND COR- RECT ASSEMBLY ON THE VEHICLE 1.
  • Page 47 V85 TT Electrical system TABLE C6 - SIDE STAND SWITCH AND COR- RECT ASSEMBLY ON THE VEHICLE • Proceed as indicated in the figure Fasten the side support on the frame (upper part) TABLE D - BRAKE LIGHT SWITCH AND COR- RECT ASSEMBLY ON THE VEHICLE •...
  • Page 48 V85 TT Electrical system TABLE D3 - BRAKE LIGHT SWITCH AND COR- RECT ASSEMBLY ON THE VEHICLE 1. Support for AMP connection 2. Small clamp TABLE E - HIGH VOLTAGE CABLES 1. Left cylinder H.V. cable H.V. cable route TABLE E1 - HIGH VOLTAGE CABLES 1.
  • Page 49 V85 TT Electrical system TABLE E3 - HIGH VOLTAGE CABLES 1. Right cylinder H.V. cable H.V. cable route TABLE E4 - HIGH VOLTAGE CABLES 1. Right cylinder cable guide TABLE E5 - HIGH VOLTAGE CABLES • Proceed as indicated in the figure Overall view of how the two H.V.
  • Page 50 V85 TT Electrical system TABLE E7 - HIGH VOLTAGE CABLES 1. Coils View of completed coils assembly TABLE F - ABS 1. ABS control unit connector Does not require dust boot. For correct connec- tion, see "installation of the ABS modulator"...
  • Page 51 V85 TT Electrical system FIGURE G2 - STARTER MOTOR 1. Power cable FIGURE G3 - STARTER MOTOR • Proceed as indicated in the figure TABLE H - EARTH POINT ON ENGINE 1. Earth cable TABLE H1 - EARTH POINT ON ENGINE 1.
  • Page 52 V85 TT Electrical system Back side TABLE A - WIRING ON THE SEAT PILLAR 1. Medium sized cable ties Once the lower seat pillar closing is mounted, re- move the two clamps (1) TABLE A1 - WIRING ON THE SEAT PILLAR •...
  • Page 53 V85 TT Electrical system TABLE A4 - WIRING ON THE SEAT PILLAR 1. Battery Place the battery as illustrated in the figure TABLE A5 - WIRING ON THE SEAT PILLAR 1. USB 2 power socket predisposition 2. Main fuses 3. Battery cover (mounted)
  • Page 54 V85 TT Electrical system TABLE B2 - COMPLETE TAILLIGHT AND LI- CENCE PLATE HOLDER (PRE-ASSEMBLY) 1. Fastening clip 2. Grey reference for positioning TABLE B3 - COMPLETE TAILLIGHT AND LI- CENCE PLATE HOLDER (PRE-ASSEMBLY) 1. Wire from wiring harness 2. Taillight wire...
  • Page 55 V85 TT Electrical system TABLE B6 - COMPLETE TAILLIGHT AND LI- CENCE PLATE HOLDER (PRE-ASSEMBLY) 1. Screws 2. Licence plate holder Close the licence plate holder (2) with the specific cover, using the screws (1) TABLE B7 - COMPLETE TAILLIGHT AND LI- CENCE PLATE HOLDER (PRE-ASSEMBLY) 1.
  • Page 56 V85 TT Electrical system TABLE C2 - REAR WHEEL SPEED SENSOR 1. Small clamp 2. Speed sensor connector Connection of the speed sensor is fastened with a clip ELE SYS - 56...
  • Page 57 V85 TT Electrical system General wiring diagram Key: 1. Multiple connectors 2. - 3. - 4. - ELE SYS - 57...
  • Page 58 V85 TT Electrical system 5. USB power sockets (not standard) 6. Left light switch 7. Horn 8. Air temperature sensor 9. Predisp. GMP/Tyre pressure 10.Instrument panel 11.Heated hand grips (not standard) 12.Derating Temp. Sens. 13.Right light switch 14.Frt. brake switch.
  • Page 59 V85 TT Electrical system 43.Neutral sensor 44.Right cylinder lambda 45.Left cylinder lambda 46.Right cylinder injector 47.Left cylinder injector 48.Coils 49.T-Map sensor 50.Motorised throttle valve 51.Demand sensor 52.Engine speed sensor 53.Engine control unit 54.Left fog light (not standard) 55.Left Frt. turn indicator 56.Front headlamp...
  • Page 60 V85 TT Electrical system Storing new keys NOTE REGARDLESS OF THE LANGUAGE SET IN THE DASHBOARD FUNCTIONS, THE KEY PRO- GRAMMING PROCEDURE CAN ONLY BE VIEWED IN ENGLISH. • To carry out the one or more key pro- gramming procedures, up to a maxi- mum of four, you must connect the motorcycle to the diagnostic tool.
  • Page 61 V85 TT Electrical system • At this point, on the digital display of the motorcycle, after the automatic restart of the dynamic presentation screen, a message will appear with a countdown of 20 seconds to insert the second key to be programmed.
  • Page 62 V85 TT Electrical system Fuses To check: • Set the ignition switch to 'OFF' to avoid an accidental short circuit. • Remove the saddle. • Remove the fuse box cover. • Take out one fuse at a time and check if the filament is broken.

  • Page 63: Control Unit

    V85 TT Electrical system Control unit REMOVAL • Remove the saddle • Unscrew and remove the screws (1) • Disconnect the connectors (2) • Remove the ECU (3) NOTE WHEN REASSEMBLING THE CONNECTORS, THE SLIDES MUST SLIDE FREELY UP TO THE LIMIT STOP, THUS FACILITATING THE CONNECTOR'S INSERTION.
  • Page 64 V85 TT Electrical system Error cause: • Corrupt Flash-eeprom (hardware problem). • Upload (e.g. in service) of an incompatible software version, therefore missing the reference check-sum. This error is indicated by lighting up in a fixed manner the general warning light.
  • Page 65 V85 TT Electrical system ELE SYS - 65...
  • Page 66 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 67 V85 TT Engine from vehicle Vehicle preparation Before removing the engine from the vehicle, the following operations must be carried out: • Place a suitable support under the vehicle and secure it using belts • Remove the battery, the fuel tank, the rider footrest plates, the sump guard, the side stand,...
  • Page 68 V85 TT Engine from vehicle • Disconnect the connector (3) • Unscrew and remove the screws (4) • Remove the left headstock cover (5) • Disconnect the connector (6) ENG VE - 68...
  • Page 69 V85 TT Engine from vehicle • Remove the clamp (7) • Unscrew and remove the screws (8) • Remove the connectors box (9) • Unscrew and remove the screws (10) ENG VE - 69...
  • Page 70 V85 TT Engine from vehicle • Remove the injector cover (11) • Undo and remove the screw (12) • Remove the left injector (13) • Remove the clamp (14) ENG VE - 70...
  • Page 71 V85 TT Engine from vehicle • Unscrew and remove the screws (15) • Remove the left intake fitting (16) • Repeat the operations from "11" to "17" to remove the right inlet fitting • Unscrew and remove the screws (17) •...
  • Page 72 V85 TT Engine from vehicle • Lift the protective boot (19) • Unscrew the nut (20) and remove it. • Remove the cable (21) • Disconnect the connector (22) ENG VE - 72...
  • Page 73 V85 TT Engine from vehicle • Unscrew and remove the screws (23) • Remove the starter motor (24). • Disconnect the connector (25) • Unscrew the nut (26) and remove it. • Remove the cable (27) and (28) ENG VE - 73...

  • Page 74: Remove The

    V85 TT Engine from vehicle • Unscrew and remove the screw (29) • Remove the oil pressure bulb cover (30) • Unscrew and remove the screw (31) • Remove the cable (32) from the oil pressure bulb • Press the lever (33) toward the front...

  • Page 75: Unscrew And Remove The

    V85 TT Engine from vehicle • Remove the clutch cable (34) from the cable grommet as indicated in the fig- • Remove the clutch cable (34) from the engine and frame area • Disconnect the connector (35) • Unscrew and remove the screws (36)
  • Page 76 V85 TT Engine from vehicle • Remove the cover (37). ENG VE - 76...
  • Page 77 INDEX OF TOPICS NGINE...
  • Page 78 V85 TT Engine TO CONSULT THE CHAPTER ABOUT THE ENGINE AND ITS COMPONENTS PLEASE REFER TO THE APPROPRIATE MANUAL: "MSS Engine V85" ENG - 78...
  • Page 79 INDEX OF TOPICS P SUPP OWER SUPPLY...
  • Page 80 V85 TT Power supply Circuit diagram Key: 1. Fuel tank 2. Fuel pump 3. Canister 4. Throttle body 5. Fuel delivery pipes 6. Fuel vapour recovery pipe 7. Check valve 8. Breather pipe 9. Intake P SUPP - 80...
  • Page 81 V85 TT Power supply Fuel pump ERBATOIO BENZINA Pos. Descrizione Tipo Quantità Coppia Note Viti fissaggio serbatoio carburante a 10 Nm (7.38 lbf ft) telaio Ghiera fissaggio pompa carburante a 20 Nm (14.75 lbf ft) serbatoio carburante Removing • Remove the fuel tank •...
  • Page 82 V85 TT Power supply • Remove the lock (2) • Remove the hose (3) • Unscrew and remove the ring nut (4) • Remove the fuel pump (5) P SUPP - 82...
  • Page 83 V85 TT Power supply Diagram key: 1. Control unit position 2. Ignition switch 3. Battery 4. Fuel pump 5. Coils 6. Instrument panel 7. Air temperature sensor 8. Throttle valve position sensor 9. Injectors 10.Crankshaft position sensor 11.Engine temperature sensor 12.Lambda probe...
  • Page 84 V85 TT Power supply 14.Gear sensor 15.Fall sensor P SUPP - 84...
  • Page 85 INDEX OF TOPICS SUSP USPENSIONS...
  • Page 86 V85 TT Suspensions Handlebar ANUBRIO OMANDI Pos. Descrizione Tipo Quantità Coppia Note Viti fissaggio cavallotti inferiori a piastra superiore di sterzo Viti fissaggio morsetto a cavallotti in- feriori a manubrio Viti fissaggio paramani e pesi antivi- 10 Nm (7.38 lbf ft)

  • Page 87: Remove The Left

    V85 TT Suspensions • Remove the left hand grip (2) • Unscrew and remove the screws (3) • Remove the left-hand lights switch cover (4) • Loosen the two screws (5) SUSP - 87...
  • Page 88 V85 TT Suspensions • Unscrew and remove the screws (6) • Loosen the screw (7) • Remove the right-hand lights switch cover (8) • Loosen the screws (9) • Unscrew and remove the screws (10) • Remove the U-bolt (11)
  • Page 89 V85 TT Suspensions • Support the handlebar • Remove the left-hand lights switch from the handlebar (12) • Remove the throttle control from the handlebar (13) • Remove the right-hand lights switch from the handlebar (14) • Remove the handlebar (15)

  • Page 90: Front Fork

    V85 TT Suspensions Front fork ORCELLA ANTERIORE Pos. Descrizione Tipo Quantità Coppia Note Viti fissaggio piedini forcella a perno 10 Nm (7.38 lbf ft) ruota SUSP - 90...

  • Page 91: Removing The Fork Legs

    V85 TT Suspensions TERZO Pos. Descrizione Tipo Quantità Coppia Note Ghiera fissaggio assieme piastra in- feriore/perno di sterzo a cannotto Controghiera fissaggio assieme piastra inferiore/perno di sterzo a cannotto Viti fissaggio steli forcella a piastra inferiore di sterzo Bussola fissaggio piastra superiore...
  • Page 92 V85 TT Suspensions Disassembling the fork NOTE THE STEMS ARE NOT THE SAME, THEREFORE THEY REQUIRE SEPARATE REMOVAL PRO- CEDURES. THE FOLLOWING OPERATIONS APPLY WHEN REMOVING THE RIGHT HAND STEM • Taking care not to damage it, secure the fork vertically in a vice, using the appropriate protection devices.
  • Page 93 V85 TT Suspensions • Extract the shaft (6) and remove it. • After removing the locking plate and the device used to compress the spring, remove the upper plate (7) and the pre-loading pipe (3). • Remove the spring (8) allowing the oil inside the stem to drip out.
  • Page 94 V85 TT Suspensions • Taking care not to damage it, secure the sleeve horizontally in a vice, using the appropriate protection devices. • Extract the dust guard (9). Specific tooling AP8140149 Guard for assembly operations • Remove the seeger ring (10) from in- side the sleeve.
  • Page 95 V85 TT Suspensions • Remove the complete plunger (13). • Observing the indicated sequence, ex- tract and remove the slider bushing (14), the guide bushing (15), the ring (16), the oil seal (17), the seeger ring (10) and the dust guard (9).
  • Page 96 V85 TT Suspensions • Unscrew and remove the cap (1). • Unscrew the special nut (2) and re- move it. • Remove the buffer (3). • Drain the oil into a container having sufficient capacity, extending the stem several times in order to ensure the oil is drained completely.
  • Page 97 V85 TT Suspensions • Taking care not to damage it, secure the sleeve horizontally in a vice, using the appropriate protection devices. • Extract the dust guard (4). Specific tooling AP8140149 Guard for assembly operations • Remove the seeger ring (5) from inside the sleeve.
  • Page 98 V85 TT Suspensions If the scratches are deep, replace the stem. Using a dial gauge, check than any bending of the stem is below the limit value. If it is over the limit, replace the stem. CAUTION A BENT STEM SHOULD NEVER BE STRAIGHTENED SINCE ITS STRUCTURE WOULD BE WEAK- ENED MAKING THE VEHICLE DANGEROUS TO USE.
  • Page 99 V85 TT Suspensions THE FOLLOWING OPERATIONS APPLY WHEN MOUNTING THE RIGHT HAND STEM • Observing the indicated sequence, ex- tract and remove the dust guard (1), the seeger ring (2), the oil seal (3), the ring (4), the guide bushing (5) and the slider bushing (6).
  • Page 100 V85 TT Suspensions • Using a suitable tool, complete with striking hammer, insert oil seal into its housing (3). Specific tooling AP8140189 Tool for fitting oil seal for 43 mm (1.69 in) diameter hole AP8140146 Weight • Position the seeger ring (2) inside the sleeve.
  • Page 101 V85 TT Suspensions • Insert the spring (10), making sure that it is aligned correctly The end where the spirals are more compressed should be facing upwards • Insert the pre-load tube (11), making sure that it is aligned correctly. The narrower part must be inserted into the spring.
  • Page 102 V85 TT Suspensions • Insert the shaft (16) into the plunger. • Before positioning the cap, adjust the hydraulic regulator screw so that the internal distance is as close as possi- ble to 13 mm (0.51 in). • Screw the cap (17) onto the plunger as far as it will go.
  • Page 103 V85 TT Suspensions • Tighten the cap on the sleeve, applying the pre-defined torque. THE FOLLOWING OPERATIONS APPLY WHEN MOUNTING THE LEFT HAND STEM • Observing the indicated sequence, ex- tract and remove the dust guard (1), the seeger ring (2), the oil seal (3), the ring (4), the guide bushing (5) and the slider bushing (6).
  • Page 104 V85 TT Suspensions • Position the seeger ring (2) inside the sleeve. • Insert the dust guard (1) into its hous- ing correctly. • Place the fork stem vertically on a work surface. • Fill the stem with the quantity of oil in- dicated in the "Refilling oil"...
  • Page 105 V85 TT Suspensions • Insert the special nut (8) and tighten it as far as it will go. • Insert the cap (9) and tighten it as far as it will go. • Ensure that the cap cannot rotate, and then tighten the nut.
  • Page 106 V85 TT Suspensions Filling oil THE FOLLOWING OPERATIONS APPLY WHEN MOUNTING THE RIGHT HAND STEM • Place the fork stem vertically on a work surface. • Fill the STEM with the indicated quan- tity of oil. WARNING OPERATE THE PLUNGER MULTIPLE TIMES UNTIL AIR BUBBLES MAY BE SEEN ON THE SURFACE OF THE OIL.

  • Page 107: Installing The Fork Legs

    V85 TT Suspensions Installing the fork legs The following procedure is described for a single fork stanchion, but is valid for both stanchions • Insert the fork stanchion (1) into the upper and lower steering yoke holes • Insert and tighten the screw (2) •...

  • Page 108: Undo And Remove The

    V85 TT Suspensions • Unscrew and remove the screws (2) • Remove the U-bolt (3) • Unscrew and remove the fastening bushing (4) • Undo and remove the screw (5) • Remove all the wiring from the cable grommet •...
  • Page 109 V85 TT Suspensions Removing • Remove the upper steering yoke • Remove the front mudguard • Remove the front wheel • Undo and remove the screw (1) • Unscrew and remove the lower ring nut (2), using the special tool •...
  • Page 110 V85 TT Suspensions • Remove the lower steering yoke (5) along with the fork stanchions • Undo and remove the screws (6) and remove the fork stanchions (7) Steering bearing TERZO Pos. Descrizione Tipo Quantità Coppia Note Ghiera fissaggio assieme piastra in-...
  • Page 111 V85 TT Suspensions Adjusting play • Remove the upper steering yoke • Remove the safety washer (1) • Unscrew and remove the upper ring nut (2), using the special tool • Remove the rubber gasket (3) • Adjust by tightening the lower ring nut to the prescribed torque •...
  • Page 112 V85 TT Suspensions • Refit the rubber gasket (3) • Mount the upper ring nut (2), manually tightening it more than 90° so that the necks of both ring nuts correspond with one another • Correctly reposition the safety washer Disassembling •...
  • Page 113 V85 TT Suspensions LOWER STEERING BEARING • Remove the lower steering bearing (4) • Remove the lower seat (5) of the lower steering bearing • Using a generic bearing puller, remove the upper seat of the lower steering bearing as indicated in the figure...
  • Page 114 V85 TT Suspensions • Insert the lower seat (1) of the lower steering bearing • Insert the lower steering bearing (2) UPPER STEERING BEARING • Using the appropriate punch, insert the lower seat of the upper steering bear- ing as illustrated in the figure •...

  • Page 115: Shock Absorbers

    V85 TT Suspensions • Insert the upper seat (4) of the upper steering bearing Shock absorbers MMORTIZZATORE Pos. Descrizione Tipo Quantità Coppia Note Vite fissaggio ammortizzatore poste- 50 Nm (36.88 lbf ft) riore su scatola trasmissione Vite fissaggio ammortizzatore poste- 50 Nm (36.88 lbf ft)
  • Page 116 V85 TT Suspensions Removing • Blocking the nut (1) • Undo and remove the screw (2) • Undo and remove the screw (3) • Retrieve the bushing (4) • Remove the shock absorber (5) SUSP - 116...
  • Page 117 INDEX OF TOPICS CHAS HASSIS...

  • Page 118: Front Wheel

    V85 TT Chassis Front wheel UOTA ANTERIORE Pos. Descrizione Tipo Quantità Coppia Note Dado fissaggio perno ruota anteriore 80 Nm (59.00 lbf ft) Removal • Place a support under the vehicle and secure it using belts so that the wheel can move freely and the vehicle does not fall.
  • Page 119 V85 TT Chassis • Unscrew and remove the screws (2) • Remove the ABS sensor (3) from the front right fork • Unscrew and remove the screws (4) • Remove the front left brake calliper (5) from the brake disc •...
  • Page 120 V85 TT Chassis • Loosen the screws (8) • Loosen the screws (9) • Unscrew the nut (10) and remove it. • Retrieve the washer (11) CHAS - 120...
  • Page 121 V85 TT Chassis • Remove the wheel axle (12) • Remove the front wheel (13) • Retrieve the washer (14) REMOVING THE FRONT BRAKE DISCS The following procedure is described for a single brake disc, but is valid for both front brake discs.
  • Page 122 V85 TT Chassis • Remove the phonic wheel (2) • Remove the front brake disc (3) FRONT WHEEL BEARING REMOVAL • Remove the front wheel • Remove the dust cover (1) • Using a generic bearing puller, remove the bearing as illustrated in the figure •...
  • Page 123 V85 TT Chassis Installing • Insert the spacer (1) • Place the front wheel (2) between the fork stanchions • Insert the wheel pin (3) • Insert the washer (4) CHAS - 123...
  • Page 124 V85 TT Chassis • Insert and tighten the nut (5) • Tighten the screws (6) • Tighten the screws (7) • Correctly place the right front brake calliper (8) • Insert and tighten the screws (9) CHAS - 124...
  • Page 125 V85 TT Chassis • Correctly place the right front brake calliper (10) • Insert and tighten the screws (11) • Position the ABS sensor (12) on the calliper mounting bracket • Insert and tighten the screws (13) • Insert the ABS sensor cable in the ca-...
  • Page 126 V85 TT Chassis FRONT BRAKE DISCS INSTALLATION The following procedure is described for a single brake disc, but is valid for both front brake discs. • Place the front brake disc (1) • Place the phonic wheel (2) • Insert and tighten the screws (3) FRONT WHEEL BEARINGS INSTALLATION •...

  • Page 127: Rear Wheel

    V85 TT Chassis • Insert the dust cover (1) • Rotate the wheel and repeat the entire operation from the opposite side of the wheel to install the second bearing Rear wheel UOTA POSTERIORE Pos. Descrizione Tipo Quantità Coppia Note Dado fissaggio perno ruota posteri- 100 Nm (73.76 lbf ft)
  • Page 128 V85 TT Chassis Rimozione • Undo and remove the screw (1) • Holding the pin (3) in place, unscrew and remove the nut (2) • Retrieve the washer (4) • Remove the pin (3) CHAS - 128...
  • Page 129 V85 TT Chassis • Remove the brake calliper support plate (5) from the brake disc, complete with rear brake calliper • Remove the rear wheel (6) • Retrieve the bushing (7) FLEXIBLE COUPLING REMOVAL • Remove the rear wheel •...
  • Page 130 V85 TT Chassis REMOVING THE REAR BRAKE DISC • Remove the rear wheel • Unscrew and remove the screws (1) • Remove the phonic wheel (2) • Remove the brake disc (3) Installing • Place the spacer (1) on the rear wheel •...
  • Page 131 V85 TT Chassis • Insert the wheel pin (4) • Insert the washer (5) • Holding the pin (6) in place, tighten the nut (7) • Insert and tighten the screw (7) CHAS - 131...
  • Page 132 V85 TT Chassis FLEXIBLE COUPLINGS INSTALLATION • Remove the rear wheel • Insert the flexible couplings (1) in the specific lodging REAR BRAKE DISC INSTALLATION • Remove the rear wheel • Place the brake disc (1) • Place the phonic wheel (2) •...
  • Page 133 V85 TT Chassis Pos. Descrizione Tipo Quantità Coppia Note Dado fissaggio perno forcellone 50 Nm (36.88 lbf ft) Perno fissaggio forcellone 50 Nm (36.88 lbf ft) Vite fissaggio passatubo freno pos- 6 Nm (4.43 lbf ft) teriore a forcellone Removing •...
  • Page 134 V85 TT Chassis • Remove the swingarm (5) Removing • Remove the footrest plates • Remove the rear wheel • Remove the swingarm • Strike a few times with a mallet to re- move the cardan shaft (1) Removing •...
  • Page 135 V85 TT Chassis • Unscrew and remove the screws (2) • Remove the bevel gear (3) Removal • Undo the gearbox cover fixing screws • Using the suitable special tool, heat the perimeter of the cover Specific tooling 020151Y Air heater...
  • Page 136 V85 TT Chassis • If available, use the threaded stud bolts as a guide to remove the cover. Turn the complete box and tapping it on a flat surface, remove the cover. • Slide off the complete cover from the crown.
  • Page 137 V85 TT Chassis • Collect the washer. • Remove the needle bearing. • Using a suitable tool, disengage the ra- dial snap ring. • Remove the radial snap ring. CHAS - 137...
  • Page 138 V85 TT Chassis • Using the special tool, heat the seat of the outer track of the needle bearing. Specific tooling 020151Y Air heater • Insert the special tool under the washer and screw the cursor. Specific tooling 001467Y036 Bearing internal cup extractor •...
  • Page 139 V85 TT Chassis • Remove the washer. • Remove the sealing ring. When reas- sembling use a new ring. • Using a suitable tool, remove the radial snap ring. • Using special tool, unscrew the ring nut. At the end of the thread, screw un-...
  • Page 140 V85 TT Chassis • Insert the special tool under the shoul- der washer and screw the cursor. Specific tooling 19.90.70.00 Extractor for internal ring on drilled bolt • Remove the inner track of the needle bearing. • Remove the shoulder washer.
  • Page 141 V85 TT Chassis • Remove the crown gear. • Remove the cover from the gearbox of the splash guard hub. • Remove the O-ring. When reassem- bling use a new O-ring. • Rotate the cover and remove the seal ring. When reassembling use a new seal ring.
  • Page 142 V85 TT Chassis • Using special tool, unscrew the pinion bearings case. Specific tooling 020998Y Pinion case wrench • Remove the complete pinion from its seat. • Using the special tool, lock in the vice, unscrew fastening nut and lock nut of the pinion case bearing.
  • Page 143 V85 TT Chassis • Remove the sealing ring. • Remove the O-ring. Checking • After assembly of the box, it is neces- sary to check the play between the pinion and the crown. Clamp in a vice and install a dial gauge by means of a suitable support.
  • Page 144 V85 TT Chassis Assembling • Insert the new O-ring in the pinion unit, or use the one removed during the dis- mantling phase if it is intact and un- damaged • Insert the seal ring until it stops • Insert the spacer closing bearings pay-...
  • Page 145 V85 TT Chassis • Insert the complete pinion in its seat. • Using special tool, screw the pinion bearings case. Specific tooling 020998Y Pinion case wrench • Using the special tool, insert a new seal ring in the cover. •...
  • Page 146 V85 TT Chassis • Insert the shoulder washer. Using the special tool, insert the inner track of the needle bearing. Insert the radial snap ring. Specific tooling GU19927900 Punch for pressing bearing inner ring onto drilled pin • Reposition the crown axle thickness.
  • Page 147 V85 TT Chassis Installing • Insert the bevel gear (1) on the swing- • Insert and tighten the fastening screws (2) to the prescribed torque • Insert and tighten the fastening screws (3) to the prescribed torque CHAS - 147...

  • Page 148: Side Stand

    V85 TT Chassis Stand AVALLETTO Pos. Descrizione Tipo Quantità Coppia Note Perno fissaggio cavalletto laterale 10 Nm (7.38 lbf ft) Dado fissaggio cavalletto laterale a 30 Nm (22.13 lbf ft) Loctite 243 supporto cavalletti Viti fissaggio supporto cavalletti a te- 50 Nm (36.88 lbf ft)
  • Page 149 V85 TT Chassis • Remove the sensor (2) and the cover (3) from the stand support • Remove the spring (4) • Holding the pin (5) in place, unscrew and remove the nut (6) • Remove the side stand (7).
  • Page 150 V85 TT Chassis • Unscrew and remove the screws (8) • Unscrew and remove the screws (9) • Remove the stand support (10) CHAS - 150...
  • Page 151 V85 TT Chassis Exhaust ARMITTA Pos. Descrizione Tipo Quantità Coppia Note Fissaggio sonda lambda 38 Nm (28.03 lbf ft) Dado fissaggio collettori di scarico a 25 Nm (18.44 lbf ft) teste motore Fascetta fissaggio compensatore a 25 Nm (18.44 lbf ft)
  • Page 152 V85 TT Chassis • Block the nut (2) so that it cannot rotate and remove the screw (3) • Remove the rear silencer (4) Removing the manifold - tail pipe • Remove the terminal • Loosen the clamp (1) •...
  • Page 153 V85 TT Chassis • Block the nut (3) so that it cannot rotate and remove the screw (4) • Block the nut (6) so that it cannot rotate and remove the screw (5) • Remove the central manifold (7) Removing the exhaust manifold •...
  • Page 154 V85 TT Chassis • Unscrew and remove the nuts (2) from both sides of the vehicle • Remove the exhaust manifold (3) CHAS - 154...
  • Page 155 V85 TT Chassis Aria secondaria key: 1. Air filter casing 2. Secondary air valve 3. Secondary air system pipe 4. Secondary air system inlets on the engine • Two auxiliary air inlets have been included in the cylinder head which, in combination with...
  • Page 156 V85 TT Chassis • Undo the screws fastening the reed valve cover. • Remove the reed valve cover • Remove the reed valve. • Remove the flame trap. CHAS - 156...
  • Page 157 V85 TT Chassis • A valve controlled by the engine ECU is installed under the tank, which al- lows air to flow towards the cylinders via two flexible hoses. • This valve is connected directly to the filter box via a flexible hose.
  • Page 158 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
  • Page 159 V85 TT Braking system MPIANTO FRENANTE Pos. Descrizione Tipo Quantità Coppia Note Vite fissaggio tubi freno a piastra in- 10 Nm (7.38 lbf ft) feriore di sterzo Vite fissaggio posteriore tubi freno a 10 Nm (7.38 lbf ft) telaio BRAK SYS - 159...

  • Page 160: Braking System

    V85 TT Braking system OMPA FRENO POSTERIORE Pos. Descrizione Tipo Quantità Coppia Note Perno fissaggio aggancio molla leva 6 Nm (4.43 lbf ft) freno posteriore a piastra telaio Vite fissaggio leva freno posteriore a 25 Nm (18.44 lbf ft) piastra telaio...
  • Page 161 V85 TT Braking system INZA FRENO POSTERIORE Pos. Descrizione Tipo Quantità Coppia Note Viti fissaggio pinza freno posteriore a 25 Nm (18.44 lbf ft) staffa supporto pinza Perno fissaggio staffa supporto pinza 35 Nm (25.81 lbf ft) posteriore BRAK SYS - 161...
  • Page 162 V85 TT Braking system INZA FRENO ANTERIORE Pos. Descrizione Tipo Quantità Coppia Note Viti fissaggio pinze freno anteriori a 50 Nm (36.88 lbf ft) piedini forcella INZA FRENO ANTERIORE Pos. Descrizione Tipo Quantità Coppia Note Viti fissaggio pinze freno anteriori a 50 Nm (36.88 lbf ft)
  • Page 163 V85 TT Braking system Foreword Key: 1. Rear brake calliper 2. Modulator 3. Front bleed valve 4. Front brake reservoir 5. Front brake callipers 6. Rear brake pump 7. Rear brake reservoir BRAK SYS - 163...
  • Page 164 V85 TT Braking system Operating diagram ABS functional diagram key 1. Front system circuit 2. Front brake master cylinder 3. Front brake control lever 4. Rear system circuit BRAK SYS - 164...
  • Page 165 V85 TT Braking system 5. Rear brake pump 6. Rear brake pedal control 7. ABS control unit 8. Rear brake calliper 9. Front calliper (2 callipers) 10.Front brake circuit intake solenoid valve (normally open) 11.Humidifier 12.Rear brake circuit intake solenoid valve (normally open) 13.Rear brake exhaust circuit solenoid valve (normally closed)
  • Page 166 V85 TT Braking system The system restores the fluid taken from the calliper (8-9) in the section of the system between the brake pump (2-5) and the ABS inlet valve (10-12). D - Pressure restoration: by opening the inlet valve (10-12) momentarily, the pressure of the callipers (8-9) is increased until maximum deceleration is reached.
  • Page 167 V85 TT Braking system Advanced functions - ABS • This function allows you to disable the ABS system that is normally active "On". • Briefly pressing the MODE selector in the middle deactivates the function ("Off") and pressing it again reactivates it ("reactivate").
  • Page 168 V85 TT Braking system • In OFF ROAD mode, the ABS system deactivates automatically for the rear wheel. CAUTION ONLY IN THIS MODE DOES THE ABS SYSTEM STAY AC- TIVE EXCLUSIVELY FOR THE FRONT WHEEL AND THE DEDICATED SYMBOL APPEARS ON THE DISPLAY TO RE- MIND THE RIDER TO TAKE PARTICULAR CARE.
  • Page 169 V85 TT Braking system • Remove the support bracket (3) • Disconnect the connector (4) • Unscrew and remove the screws (5) • Remove the ABS control unit (6) NOTE FIRST OF ALL, DISCONNECT THE LINES BETWEEN THE ABS CONTROL UNIT AND THE BRAKE MASTER CYLIN-...
  • Page 170 V85 TT Braking system • Fill the reservoirs and refit the caps • Check the stroke and sensitivity of the front brake lever and the rear brake pedal • If the brake pedal or lever stroke is too long after carrying out the bleeding procedure, check the braking system for leaks and, if none are found, bleed the system using the diagnostic tool, as described.

  • Page 171: Disconnect The

    V85 TT Braking system Component maintenance • The vehicle is equipped with two-chan- nel ABS. In other words, it works on both the front and rear wheel. Periodi- cally and each time the wheels are re- mounted, the phonic wheel or the...
  • Page 172 V85 TT Braking system BEFORE REFITTING, ENSURE THAT THE CONTACT SURFACES BETWEEN THE SENSOR AND THEIR SEATS ARE FREE OF IMPERFECTIONS AND PERFECTLY CLEAN. ALWAYS CHECK THE DISTANCE BETWEEN THE SENSOR AND THE PHONIC WHEEL. Removal • Connect the bleeder bottles to the cal- liper bleeder screw and open •...
  • Page 173 V85 TT Braking system • Remove the rear calliper (5) Installing • Remove the rear brake calliper • Correctly position the new rear brake calliper (1) on the brake disc • Insert and tighten the screws (2) • Position the brake line, insert and tight- en the screw (3) •...
  • Page 174 V85 TT Braking system • Insert and tighten the two grub screws • Remove the clamp from the brake pedal. • Remove the brake fluid reservoir cap and fill it with new brake fluid CAUTION PERFORM THE STANDARD BRAKING SYSTEM BLEEDING PROCEDURE, AS DESCRIBED AT THE END OF THE CHAPTER.
  • Page 175 V85 TT Braking system • Remove the front brake calliper (3) Installing • Remove the front brake calliper • Correctly position the new front brake calliper (1) on the brake disc • Insert and tighten the screws (2) • Position the brake line on the brake...
  • Page 176 V85 TT Braking system • Disconnect the flexible bleeder pipes and re-tighten the bleeder screws, applying the correct torque Disc Inspection FRONT CAUTION THE FRONT BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE SPECIFICATIONS OF THE SYSTEM. •...
  • Page 177 V85 TT Braking system • Remove the front brake calliper (2) from the brake disc • Remove the two retaining springs (3) • Remove the two pins (4) • Remove the spring (5) BRAK SYS - 177...
  • Page 178 V85 TT Braking system • Remove the brake pads (6) one at a time CAUTION AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKAGE.
  • Page 179 V85 TT Braking system • Insert the two retaining springs (4) • Insert the front brake calliper (5) on the brake disc • Insert the two screws (6) and tighten them • Insert the front brake calliper (5) on the...
  • Page 180 V85 TT Braking system • Insert the two screws (6) and tighten them Removal • Connect the bleeder bottles to the cal- liper bleeder screw and open • Press the lever down as far as it will go and block it in position using a clamp-...
  • Page 181 V85 TT Braking system • Remove the rear brake calliper (4) from the brake disc • Unscrew and remove the two grub screws (5). • Remove the brake pads (6) one at a time CAUTION AFTER REMOVING THE PADS, DO NOT OPERATE THE...
  • Page 182 V85 TT Braking system • Insert and tighten the grub screws (2) • Insert the rear brake calliper (3) on the brake disc • Insert and tighten the screws (4) • Insert the brake calliper line into the cable grommet (5)
  • Page 183 V85 TT Braking system • Tighten the two grub screws (2) Bleeding the braking system PREPARING THE VEHICLE • It is important to ensure that there is always a sufficient quantity of brake fluid in the tank. • These operations may be simplified by using a bleeding device when carrying out the "Re- placing the brake fluid"...
  • Page 184 V85 TT Braking system FRONT • With diagnostics instrument properly connected, select the function "FRONT BRAKE BLEEDING PROCEDURE". • The pump starts rotating. • While the pump is performing a rotation cycle, operate and release the front brake lever until the message diagnostics instrument cycle completion is received.
  • Page 185 V85 TT Braking system tainer, this will release the tension on the brake lever, risking making it arrive at the end stop. • Close the bleed valve before arriving at the end of the stroke with the lever. • Repeat the operation until the are no air bubbles in the fluid going into the container.
  • Page 186 V85 TT Braking system • Repeatedly quickly pull and release the rear brake lever, then keep it fully pulled. • Loosen the bleed valve by a 1/4 turn so that the brake fluid flows into the con- tainer, this will release the tension on the brake lever, risking making it arrive at the end stop.
  • Page 187 V85 TT Braking system • Unscrew and remove the screws (2) • Remove the U-bolt (3) • Unscrew and remove the two screws • Remove the sensor (5) from the front brake master cylinder BRAK SYS - 187...
  • Page 188 V85 TT Braking system • Remove the front brake master cylin- der (6) Rimozione • Unscrew and remove the two screws • Remove the protection cover (2) • Undo and remove the joint screw (3) from the rear brake master cylinder af- ter placing a suitable container under- neath to collect the brake fluid.
  • Page 189 V85 TT Braking system • Remove the rear brake master cylinder REAR BRAKE FLUID RESERVOIR REMOVAL • Remove the rear brake master cylinder • Undo and remove the screw (1) • Retrieve the support bracket (2) • Remove the hose guide (3) •...
  • Page 190 V85 TT Braking system • Remove the rear brake master cylinder plunger (3) BRAK SYS - 190...
  • Page 191 INDEX OF TOPICS BODYW ODYWORK...
  • Page 192 V85 TT Bodywork ANO SOTTOSELLA Pos. Descrizione Tipo Quantità Coppia Note Vite fissaggio passatubo freno ante- 6 Nm (4.43 lbf ft) riore a scatola batteria Viti fissaggio scatola batteria a telaio 6 Nm (4.43 lbf ft) Viti fissaggio staffa batteria/vano por- 6 Nm (4.43 lbf ft)
  • Page 193 V85 TT Bodywork ELAIO Pos. Descrizione Tipo Quantità Coppia Note Viti fissaggio staffa supporto silen- 10 Nm (7.38 lbf ft) ziatore a telaio Viti fissaggio telaio a motore 50 Nm (36.88 lbf ft) Viti fissaggio staffa supporto regola- 10 Nm (7.38 lbf ft)
  • Page 194 V85 TT Bodywork ERRATURE Pos. Descrizione Tipo Quantità Coppia Note Vite fissaggio commutatore di accen- 25 Nm (18.44 lbf ft) sione a telaio Vite fissaggio commutatore di accen- Vite a strappo fino a sione a telaio rottura Viti fissaggio tappo serbatoio carbur- 6 Nm (4.43 lbf ft)
  • Page 195 V85 TT Bodywork ERBATOIO BENZINA Pos. Descrizione Tipo Quantità Coppia Note Viti fissaggio serbatoio carburante a 10 Nm (7.38 lbf ft) telaio Ghiera fissaggio pompa carburante a 20 Nm (14.75 lbf ft) serbatoio carburante BODYW - 195...
  • Page 196 V85 TT Bodywork ROTEZIONI Pos. Descrizione Tipo Quantità Coppia Note Viti fissaggio parasteli a steli forcella 6 Nm (4.43 lbf ft) Viti fissaggio coperture cannotto a Autofilettanti 3 Nm (2.21 lbf ft) scatole connettori 3x20 Viti fissaggio inferiore scatole con- 6 Nm (4.43 lbf ft)
  • Page 197 V85 TT Bodywork OMPA FRENO POSTERIORE Pos. Descrizione Tipo Quantità Coppia Note Perno fissaggio aggancio molla leva 6 Nm (4.43 lbf ft) freno posteriore a piastra telaio Vite fissaggio leva freno posteriore a 25 Nm (18.44 lbf ft) piastra telaio...
  • Page 198 V85 TT Bodywork EDANE Pos. Descrizione Tipo Quantità Coppia Note Viti fissaggio supporti pedane pas- 25 Nm (18.4 lbf ft) seggero a supporto telaio Viti fissaggio gomma pedane a ped- 10 Nm (7.38 lbf ft) Viti fissaggio protezione paratacco 10 Nm (7.38 lbf ft)
  • Page 199 V85 TT Bodywork ARAFANGO POSTERIORE Pos. Descrizione Tipo Quantità Coppia Note Viti fissaggio chiusura portatarga a Autofilettante 3 Nm (2.21 lbf ft) portatarga 3.9x14 Viti fissaggio portatarga a telaio 8 Nm (5.90 lbf ft) Viti fissaggio portatarga a scatola Autofilettante 3 Nm (2.21 lbf ft)
  • Page 200 V85 TT Bodywork ANUBRIO OMANDI Pos. Descrizione Tipo Quantità Coppia Note Viti fissaggio cavallotti inferiori a piastra superiore di sterzo Viti fissaggio morsetto a cavallotti in- feriori a manubrio Viti fissaggio paramani e pesi antivi- 10 Nm (7.38 lbf ft)
  • Page 201 V85 TT Bodywork EVA CAMBIO Pos. Descrizione Tipo Quantità Coppia Note Vite fissaggio leva cambio a piastra 25 Nm (18.44 lbf ft) sinistra telaio Dado fissaggio tirante comando Manuale con dima cambio a leva cambio Dado fissaggio tirante comando Manuale con dima...
  • Page 202 V85 TT Bodywork ANALE POSTERIORE Pos. Descrizione Tipo Quantità Coppia Note Viti fissaggio fanale posteriore a por- Autofilettante 3 Nm (2.21 lbf ft) tatarga 5x14 Viti fissaggio indicatori di direzione 3 Nm (2.21 lbf ft) Con dado autobloc- posteriore a portatarga...
  • Page 203 V85 TT Bodywork UPOLINO ARABREZZA Pos. Descrizione Tipo Quantità Coppia Note Viti fissaggio anteriore supporto par- 10 Nm (7.38 lbf ft) abrezza a telaietto anteriore Viti fissaggio posteriore supporto 10 Nm (7.38 lbf ft) parabrezza a telaietto anteriore Viti fissaggio bussole supporto para- 10 Nm (7.38 lbf ft)
  • Page 204 V85 TT Bodywork ORPO FARFALLATO Pos. Descrizione Tipo Quantità Coppia Note Viti fissaggio cappucci iniettori a rac- 6 Nm (4.43 lbf ft) cordi di ammissione OPRISERBATOIO Pos. Descrizione Tipo Quantità Coppia Note Viti fissaggio cover blocchetto accen- 4 Nm (2.95 lbf ft)
  • Page 205 V85 TT Bodywork Pos. Descrizione Tipo Quantità Coppia Note Viti fissaggio cover tappo serbatoio a 4 Nm (2.95 lbf ft) serbatoio carburante Colonnette fissaggio supporto cover 4 Nm (2.95 lbf ft) serbatoio laterali a serbatoio carbur- ante Viti fissaggio anteriore cover serba- 4 Nm (2.95 lbf ft)
  • Page 206 V85 TT Bodywork ARROZZERIA CENTRALE Pos. Descrizione Tipo Quantità Coppia Note Viti fissaggio fianchetti a telaio 6 Nm (4.43 lbf ft) ASSA FILTRO Pos. Descrizione Tipo Quantità Coppia Note Viti fissaggio cassa filtro a telaio 10 Nm (7.38 lbf ft)
  • Page 207 V85 TT Bodywork Pos. Descrizione Tipo Quantità Coppia Note Viti fissaggio trombetta di aspira- TCB 4.2x16 3 Nm (2.21 lbf ft) zione a coperchio cassa filtro Viti fissaggio corpo farfallato a coper- 10 Nm (7.38 lbf ft) chio cassa filtro Viti fissaggio filtro aria a scatola filtro 3 Nm (2.21 lbf ft)
  • Page 208 V85 TT Bodywork • Remove the luggage rack cover (2) LUGGAGE RACK REMOVAL • Unscrew and remove the screws (1) • Unscrew and remove the screws (2) • Remove the luggage rack (3) BODYW - 208...
  • Page 209 V85 TT Bodywork Hand guards REMOVAL The following procedure is described for a single handguard, but is valid for both handguards. • Remove the rear view mirrors • Undo and remove the screw (1) • Remove the handguards (2) •...

  • Page 210: Instrument Panel

    V85 TT Bodywork • Holding the locknut (2) so it cannot ro- tate, loosen the nut (3) • Remove the rear view mirror (4) • Undo and remove the locknut (2) Instrument panel REMOVAL • Remove the headlight • Unscrew and remove the screws (1)
  • Page 211 V85 TT Bodywork • Disconnect the connector (2) • Remove the instrument panel (3) Headlight assy. REMOVAL • Remove the top fairing • Unscrew and remove the screws (1) • Unscrew and remove the screws (2) BODYW - 211...
  • Page 212 V85 TT Bodywork • Remove the cover (3). • Remove the connector (4) from the support as indicated in the figure • Disconnect the connector (4) • Undo and remove the screw (5) BODYW - 212...
  • Page 213 V85 TT Bodywork • Undo and remove the screw (6) • Undo and remove the screw (7) • Remove the wiring as indicated in the figure • Remove the front light assembly (8) BODYW - 213...

  • Page 214: Turn Indicators

    V85 TT Bodywork • Retrieve the bushings (9) Horn REMOVAL • Disconnect the connectors (1) • Undo and remove the screw (2) • Remove the horn (3) Turn indicators REMOVING FRONT TURN INDICATORS • Remove the top fairing • Disconnect the left turn indicator con- nector (1) •...
  • Page 215 V85 TT Bodywork • Unscrew and remove the screws (3) from both sides of the vehicle • Remove the front turn indicators (4) from both sides of the vehicle REAR TURN INDICATORS REMOVAL • Block the nuts (1) so that they cannot...
  • Page 216 V85 TT Bodywork Headlight fairing REMOVAL • Unscrew and remove the screws (1) • Remove the top fairing (2) TOP FAIRING BRACKET REMOVAL • Unscrew and remove the screws (1) • Unscrew and remove the screws (2) BODYW - 216...
  • Page 217 V85 TT Bodywork • Remove the support (3) Disassembling the lock REMOVAL • Remove the licence plate holder brack- • Unhook and remove the wire (1) from its seat • Remove the wire (1) from the point in- dicated in the figure •...

  • Page 218: License Plate Light

    V85 TT Bodywork • Remove the saddle lock (3) Taillight assy. • Remove the licence plate holder brack- • Unscrew and remove the screws (1) • Remove the rear light assembly (2) License plate light REMOVAL • Remove the licence plate holder brack- •...
  • Page 219 V85 TT Bodywork • Remove the licence plate light (2) Footrest REMOVING THE PASSENGER FOOTRESTS The following procedure is described for a single footrest, but is valid for both passenger footrests. • Remove the snap ring(1) • Remove the pin (2) •...
  • Page 220 V85 TT Bodywork • Retrieve the two plates (4), the sphere (5) and the spring (6) REMOVING THE PASSENGER FOOTREST SUPPORT The following procedure is described for a single bracket, but is valid for both passenger footrest brackets. • Unscrew and remove the two screws •...
  • Page 221 V85 TT Bodywork • Remove the pin (2) • Remove the rider footrest (3) REMOVING THE GEAR SHIFT LEVER • Remove the safety clip (1) from the gear shift lever • Remove the gear shift lever from the spherical joint (2)
  • Page 222 V85 TT Bodywork • Undo and remove the screw (3) • Remove the gear lever (4) • Retrieve the bushing (5) and the two O- rings (6) REMOVING THE REAR BRAKE LEVER • Holding the nut (2) so that it cannot ro-...
  • Page 223 V85 TT Bodywork • Remove the rear brake lever (3) • Retrieve the nut (2) and the washer (4) • Retrieve the bushing (5) and the two O- rings (6) RIGHT RIDER FOOTREST BRACKET REMOV- • Remove the rear brake master cylin-...
  • Page 224 V85 TT Bodywork • Undo and remove the screw (2) • Undo and remove the screw (3) • Retrieve the bushing (4) • Undo and remove the screw (5) • Retrieve the bushing (6) • Hold the nut (7) from the opposite side...
  • Page 225 V85 TT Bodywork • Rotate the plate 180°, undo and re- move the screws (9) and remove the bracket (10) • Undo and remove the screw (11) and remove the sensor (12) from the brack- • Remove the right rider footrest bracket plate (13) •...
  • Page 226 V85 TT Bodywork • Remove the gear shift lever from the spherical joint (2) • Undo and remove the screw (3) • Undo and remove the screw (4) • Undo and remove the screw (5) and retrieve the bushing (6)
  • Page 227 V85 TT Bodywork • Undo and remove the screw (7) and retrieve the bushing (8) • Holding the screw (9) from the opposite side so that it cannot rotate, undo and remove the nut (10) • Rotate the plate 180° and remove the two cable grommets (11) •...
  • Page 228 V85 TT Bodywork Side body panels REMOVAL The following procedure is described for a single side panel, but is valid for both side panels. • Remove the glove compartment • Unscrew and remove the screws (1) • Remove the side fairing panel (2)
  • Page 229 V85 TT Bodywork • Remove the glove compartment (3) Side fairings REMOVAL • Remove the fuel tank • Unscrew and remove the screws (1) • Unscrew and remove the screws (2) • Unscrew and remove the screws (3) BODYW - 229...
  • Page 230 V85 TT Bodywork • Unscrew and remove the screws (4) • Remove the left side engine fairing (5) • Remove the right side engine fairing Fairing mounting panels REAR BRAKE HOSE GUIDE REMOVAL • Undo and remove the screw (1)
  • Page 231 V85 TT Bodywork • Undo and remove the screw (2) • Remove the cable grommet (3) • Remove the rear brake hose guide (4) UNDER-SADDLE COMPARTMENT/BATTERY BOX REMOVAL • Remove the side fairing panels • Remove the licence plate holder brack- •...
  • Page 232 V85 TT Bodywork • Unscrew and remove the screws (2) • Unscrew and remove the screws (3) • Unscrew and remove the screws (4) • Unscrew and remove the screws (5) BODYW - 232...
  • Page 233 V85 TT Bodywork • Remove the under-saddle compart- ment/battery box (6) License plate holder LICENCE PLATE HOLDER BRACKET REMOV- • Remove the luggage rack • Unscrew and remove the screws (1) • Unscrew and remove the screws (2) • Support the licence plate bracket •...
  • Page 234 V85 TT Bodywork • Remove the licence plate bracket cov- er (4) • Remove the wiring from the cable glands (5) • Remove the wiring from the cable glands (6) • Disconnect the right turn indicator con- nector (7) •...
  • Page 235 V85 TT Bodywork • Disconnect the connector (9) • Remove the licence plate light (10) • Remove the licence plate holder (11) complete with rear light assembly and rear turn indicators • Remove the rear light cluster • Remove the rear turn indicators...
  • Page 236 V85 TT Bodywork • Remove the filter box (2) • Unscrew the screws (3) • Unscrew and remove the screws (4) • Loosen the clamp (5) • Disconnect the pipe (6) BODYW - 236...
  • Page 237 V85 TT Bodywork • Remove the plastic rivet (7) • Unscrew and remove the screws (8) • Disconnect the connector (9) • Momentarily remove the support bracket (10) from the frame • Loosen the clamp (11) • Disconnect the pipe (12) •...

  • Page 238: Fuel Tank

    V85 TT Bodywork • Remove the filter box cover (14) com- plete with throttle body • Slide the throttle body out and remove Sump guard REMOVAL • Unscrew and remove the screws (1) • Remove the sump guard (2) Fuel tank •...
  • Page 239 V85 TT Bodywork • Undo and remove the screw (3) • Remove the ignition switch assembly cover (4) • Unscrew and remove the screws (5) • Undo and remove the screw (6) BODYW - 239...
  • Page 240 V85 TT Bodywork • Disconnect the connector (7) • Disconnect the fuel pump hose (8) • Loosen the clamp (9) and disconnect the hose (10) • Lifting the front part of the fuel tank, loosen the clamp (11) and disconnect...
  • Page 241 V85 TT Bodywork • Remove the fuel tank (13) TANK FILLER CAP REMOVAL • Open the tank filler cap • Unscrew and remove the screws (1) • Remove the tank filler cap (2) CENTRAL TANK FAIRING REMOVAL • Undo and remove the screw (1)
  • Page 242 V85 TT Bodywork • Unscrew and remove the screws (2) • Undo and remove the screw (3) • Unscrew and remove the screws (4) • Remove the central tank fairing (5) BODYW - 242...

  • Page 243: Front Mudguard

    V85 TT Bodywork Front mudguard REMOVAL • Unscrew and remove the nuts (1) • Remove the cable grommets from both sides of the mudguard (2) • Remove the complete front mudguard • Retrieve the bushings (4) BODYW - 243...
  • Page 244 V85 TT Bodywork • Unscrew and remove the screws (5) • Remove the mudguard cover (6) • Undo and remove the screws (7) • Remove the grille (8) BODYW - 244...
  • Page 245 V85 TT Bodywork Instrument cluster support REMOVAL • Remove the instrument panel • Unscrew and remove the screws (1) • Remove the instrument panel bracket • Remove the connector (3) from the guide indicated in the figure • Disconnect the connector (3) •...
  • Page 246 V85 TT Bodywork • Remove the plastic rivets from both sides of the vehicle (5) • Unscrew and remove the screws (6) • Remove the support (7) • Remove the USB socket (8) BODYW - 246...
  • Page 247 V85 TT Bodywork • Remove the connector (14) from the guide indicated in the figure • Disconnect the connector (14) • Remove the main wiring harness (15) from the bracket • Remove the support (16) • Remove the clamp (17) •...

  • Page 248: Lift The Protective

    V85 TT Bodywork Battery REMOVAL • Remove the glove compartment • Undo and remove the screw (1) • Remove the negative cable from the battery (2) • Refit the screw (1) along with the yoke in the specific seat •...
  • Page 249 V85 TT Bodywork • Remove the rear fairing (3) • Undo and remove the screw (4) • Remove the right rear fairing (5) • Undo and remove the screw (6) BODYW - 249...
  • Page 250 V85 TT Bodywork • Remove the left rear fairing (7) Copertura terminale REMOVAL • Unscrew and remove the screws (1) • Remove the left cover (2) • Unscrew and remove the screws (3) BODYW - 250...
  • Page 251 V85 TT Bodywork • Remove the terminal cover (4) • Retrieve the washers (5) BODYW - 251...
  • Page 252 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 253 V85 TT Pre-delivery Specific operations for the vehicle WINDSHIELD KIT ASSEMBLY • The box containing the windshield is in the vehicle packaging. The installation hardware is mounted on the windshield bracket assembled to the vehicle • Installation begins with the removal of...
  • Page 254 V85 TT Pre-delivery • Installation of the handguards begins with the insertion of the rubber piece (1) in the specific cylindrical lodging on the internal side of the handguards. • Then, rest the anti-vibration weight (2) in correspondence to the end of the...
  • Page 255 V85 TT Pre-delivery • Place the battery in the appropriate lodging and connect it, taking care to observe the polarity • Refit the battery cover, inserting it in the appropriate lodgings as indicated in figure "C" • Insert the screws (1) in the appropriate...
  • Page 256 ABS: Air filter: 22 Battery: 248 Bulbs: CAN line: 64 Clutch: 28 Electrical system: 8, 32 Exhaust: 151, 153 Exhaust manifold: 153 Fairings: 207, 229 Fork: 90–92, 98, 107 Front wheel: 118 Fuel: 81, 238 Fuel pump: 81 Fuses: 62 Handlebar: 86 Headlight: 29, 211, 216 Horn: 214...
  • Page 257 Oil filter: 21 Rear wheel: 127 Recommended products: 17 Scheduled maintenance: 16 Shock absorbers: 115 Side fairings: 207, 229 Side stand: 148 Spark plug: 17 Spark plugs: Stand: 148 Tank: 238 Transmission: 8 Turn indicators: 214 Tyres: 10 Windshield: Wiring diagram: 57...

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