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 PRE DE DELIVERY 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...
  • Page 6 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 7 V85 TT Pre-delivery Carry out the listed checks before delivering the motorcycle. WARNING HANDLE FUEL WITH CARE. CAUTION USE THE DIAGNOSTIC TOOL TO CHECK FOR ANY ERRORS AND CHECK THAT ALL PARAM- ETERS ARE CORRECT. ENSURE THAT THE VEHICLE CALIBRATION HAS BEEN UPDATED TO LATEST VERSION AVAILABLE, AFTER UPDATING THE DIAGNOSTIC TOOL.
  • Page 8 V85 TT Pre-delivery - Electric helmet compartment lock release switch (if applicable) - Through the diagnostic tool, check that the last mapping version is present in the control unit/s and, if required, program the control unit/s again: consult the technical service website to know about avail- able upgrades and details regarding the operation.
  • Page 9 V85 TT Pre-delivery • Apply pressure to the container to break the seals. The liquid will begin to flow into the cells. • Check that air bubbles come out of the cells; let the liquid flow into the cells for at least 20 minutes.
  • Page 10 V85 TT Pre-delivery • Front and rear brake efficiency • Front and rear suspension efficiency • Abnormal noise Static test Static control after the test drive: • Restarting when warmed up • Minimum holding (turning the handlebar) • Uniform turning of the steering •...
  • Page 11 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 12 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 13 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 14 V85 TT Pre-delivery ANDLEBAR KIT TIGHTENING TORQUES Tightening torque chart Tightening torques Residual torque Nm Nm (lbf ft) (lbf ft) Upper U-bolt fastening 25 Nm +/- 10% (18.44 20 Nm (14.75 lbf bft) lbf ft +/- 10%) LOCK ASSEMBLY ON THE CASES...
  • Page 15 V85 TT Pre-delivery • Position the latch bolt (6) in the direc- tion indicated, the spring washer (7) and relative fixing screw (8). NOTE MAKE SURE THE SPRING WASHER IS ASSEMBLED COR- RECTLY AS SHOWN IN THE IMAGE. Locking torques (N*m) Locking hook locking screw 3 Nm (2.21 lbf ft) + Loct.
  • Page 16 V85 TT Pre-delivery • Insert the locking nut (3) of the pawl and tighten it to the prescribed torque. Locking torques (N*m) Pawl lock nut 10 Nm (7.38 lb ft) • Position the spacer washer (4) and the spring washer (5) and check the cor- rect position •...
  • Page 17 V85 TT Pre-delivery • Position the pre-assembled support on the case and secure it with the four screws (12) tightening them to the pre- scribed torque. Locking torques (N*m) Case support fixing screws 3.5 Nm (2.58 lb ft) INSTALLATION OF CLOSURE LEVERS ON CASES...
  • Page 18 V85 TT Pre-delivery • Turn the key of the side lock fully anti- clockwise and move the case forward for the entire length of the connector slots. • With a final push on the rear of the case, make sure the case has arrived at the end of the connector slots.
  • Page 19 INDEX OF TOPICS CHAR HARACTERISTICS...
  • Page 20 V85 TT Characteristics Rules Safety rules Carbon monoxide If you need to keep the engine running while working on the vehicle, please ensure that you do so in an open or very well ventilated area. Never run the engine in an enclosed area. If you do work in an enclosed area, make sure to use a fume extraction system.
  • Page 21 V85 TT Characteristics BRAKE FLUID CAN DAMAGE PAINT FINISH, PLASTIC AND RUBBER. WHEN SERVICING THE BRAKING SYSTEM, PROTECT THESE COMPONENTS WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE EYEWEAR WHEN WORKING ON THE BRAKE SYSTEM. BRAKE FLUID IS EX- TREMELY HARMFUL FOR THE EYES. IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THE EYES IMMEDIATELY WITH PLENTY OF COOL, CLEAN WATER AND SEEK IMMEDIATE MEDICAL ATTENTION.
  • Page 22 CAUTION THE BEARING MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE THEY MUST BE REPLACED. • Use only ORIGINAL Moto Guzzi SPARE PARTS. • Always use the recommended lubricants and consumable material. • Lubricate the parts (when possible) before reassembling them.
  • Page 23 That is to permit the adequate adjustment of the pad friction material to the brake discs. AFTER THE SPECIFIED MILEAGE, TAKE THE VEHICLE TO AN OFFICIAL Moto Guzzi DEALER FOR THE CHECKS INDICATED IN THE "AFTER RUN-IN" TABLE IN THE SCHEDULED MAINTE- NANCE SECTION TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHI- CLE.
  • Page 24 Maximum width 950 mm (37.40 in) Height (with adjustable windshield) (V85 TT) 1300 - 1325 mm (51.18 - 52.17 in) Height (with adjustable windshield) (V85 TT Travel) 1420 - 1445 mm (55.90 - 56.89 in) Wheelbase 1530 mm (60.24 in) Kerb weight (V85 TT) 229 kg (504.86 in)
  • Page 25 9.76 cu in (160 cc) MAX Seats Maximum carrying load (V85 TT) 987.67 (448 Kg) (rider + passenger + luggage) Maximum carrying load (V85 TT Travel) 1016.33 lb (461 Kg) (rider + passenger + luggage) Electrical system ELECTRICAL SYSTEM Specification Desc./Quantity...
  • Page 26 V85 TT Characteristics INDICATOR LAMPS Specification Desc./Quantity Gearbox in neutral High beam light Cruise control warning light ABS warning light MI warning light Turn indicators Overspeed threshold / gear shift warning lights Immobilizer warning light Fuel reserve MGCT warning light...
  • Page 27 V85 TT Characteristics Specification Desc./Quantity CAUTION When using anti-skid wheels it is recommended to de- crease the inflation pressure by 0.2 bar (20 Kpa) (2.90 PSI) at the front and 0.3 bar (30 Kpa) (4.35 PSI) at the rear. WHEEL RIMS Specification Desc./Quantity...
  • Page 28 V85 TT Characteristics Pos. Description Type Quantity Torque Notes Screws fixing the clutch switch to Manual clutch control lever Clutch control lever fastening screw 8 Nm (5.9 lb ft) Screws pre-moun- ted on the control OP FAIRING INDSHIELD Pos. Description...
  • Page 29 V85 TT Characteristics EADLIGHT UNIT Pos. Description Type Quantity Torque Notes Upper screws fastening the front 10 Nm (7.38 lbf ft) headlamp to the front frame Lower screw fastening the front 10 Nm (7.38 lbf ft) headlamp to the front frame Screws fastening the direction indi- 8 Nm (5.90 lb ft)
  • Page 30 V85 TT Characteristics RONT FORK Pos. Description Type Quantity Torque Notes Screws fastening the calliper mount- 10 Nm (7.38 lbf ft) ing bracket to the wheel axle - E4 RONT WHEEL Pos. Description Type Quantity Torque Notes Nut fastening the front wheel axle M25x1.5...
  • Page 31 V85 TT Characteristics - E5 RONT WHEEL Pos. Description Type Quantity Torque Notes Nut fastening the front wheel axle M25x1.5 80 Nm (59.01 lbf ft) ANDLEBAR ONTROLS Pos. Description Type Quantity Torque Notes Screws fastening the lower U-bolts to 50 Nm (36.88 lb ft)
  • Page 32 V85 TT Characteristics Pos. Description Type Quantity Torque Notes Screws fastening the lower U-bolt 25 Nm (18.44 lbf ft) clamp to the handlebar Screws fastening the handguards 10 Nm (7.38 lbf ft) and anti-vibration weights to the han- dlebar Screws fastening the rear left shell to 1.5 Nm (1.11 lb ft)
  • Page 33 V85 TT Characteristics RONT BRAKE CALLIPER Pos. Description Type Quantity Torque Notes Screws fastening the front brake cal- 50 Nm (36.88 lb ft) liper to the calliper mounted bracket CHAR - 33...
  • Page 34 V85 TT Characteristics RONT BRAKE MASTER CYLINDER Pos. Description Type Quantity Torque Notes Screws fastening the front brake 10 Nm (7.38 lbf ft) Screws pre-assem- master cylinder clamp to the handle- bled on the master bars cylinder Brake pump cover fixing screws 0.8-1.5 Nm (0.59-1.11...
  • Page 35 V85 TT Characteristics ILTER BOX Pos. Description Type Quantity Torque Notes Screws fastening the filter casing to 10 Nm (7.38 lbf ft) the frame Screws fastening the intake duct to TCB 4.2x16 3 Nm (2.21 lbf ft) the filter casing cover Screws fastening the throttle body to 10 Nm (7.38 lbf ft)

  • Page 36: Table Of Contents

    V85 TT Characteristics TAND Pos. Description Type Quantity Torque Notes Side stand retainer pin 10 Nm (7.38 lbf ft) Nut fastening the side stand to the 30 Nm (22.13 lb ft) Loctite 243 stand mounting Screws fastening the stand mounting 50 Nm (36.88 lb ft)

  • Page 37: Pos

    V85 TT Characteristics UEL TANK COVER Pos. Description Type Quantity Torque Notes Screws fastening the ignition block 4 Nm (2.95 lb ft) cover to the tank cap cover Screws fastening the tank cap cover 4 Nm (2.95 lb ft) to the fuel tank Stud bolt fastening the side tank cov- 4 Nm (2.95 lb ft)
  • Page 38 V85 TT Characteristics BRAKING SYSTEM Pos. Description Type Quantity Torque Notes Screw fastening the brake pipe to the 10 Nm (7.38 lbf ft) lower steering plate Rear screw fastening the brake pipe 10 Nm (7.38 lbf ft) to the frame...

  • Page 39: Type Quantity

    V85 TT Characteristics - E4 ETROL VAPOUR RECOVERY SYSTEM Pos. Description Type Quantity Torque Notes Screw fastening the coil support 10 Nm (7.38 lbf ft) plate to the ABS system - E5 ETROL VAPOUR RECOVERY SYSTEM Pos. Description Type Quantity...

  • Page 40: Torque Notes

    V85 TT Characteristics EARBOX LEVER Pos. Description Type Quantity Torque Notes Screw fastening left frame plate to 25 Nm (18.44 lbf ft) the gearbox Nut fastening the gear control link- Manual with tem- age to the gear lever plate Nut fastening the gear control link-...
  • Page 41 V85 TT Characteristics - E4 ILENCER Pos. Description Type Quantity Torque Notes Lambda probe fastener 38 Nm (28.03 lb ft) Nut fixing exhaust manifolds to en- 25 Nm (18.44 lbf ft) gine Clamp fastening the compensator to 25 Nm (18.44 lbf ft)
  • Page 42 V85 TT Characteristics OOTRESTS Pos. Description Type Quantity Torque Notes Screws for fastening the passenger's 25 Nm (18.4 lb ft) footrests supports to the frame sup- port Screws fastening the footrest rubber 10 Nm (7.38 lbf ft) to the footrest Screws fastening the passenger heel 10 Nm (7.38 lbf ft)

  • Page 43: Pin Fastening The Rear Brake Lever

    V85 TT Characteristics EAR BRAKE PUMP Pos. Description Type Quantity Torque Notes Pin fastening the rear brake lever 6 Nm (4.43 lbf ft) spring coupling to the frame plate Screw fastening the rear brake lever 25 Nm (18.44 lbf ft)
  • Page 44 V85 TT Characteristics UEL TANK Pos. Description Type Quantity Torque Notes Screws fastening the fuel tank to 10 Nm (7.38 lbf ft) frame Ring nut fastening the fuel pump to 20 Nm (14.75 lbf ft) the fuel tank CHAR - 44...

  • Page 45: Screw Fastening The Rear Stop Switch M5

    V85 TT Characteristics OCKS Pos. Description Type Quantity Torque Notes Screw fastening the starter switch to 25 Nm (18.44 lbf ft) the frame Screw fastening the starter switch to Shear head screw the frame until it breaks Screws fastening the fuel tank cap to 6 Nm (4.43 lbf ft)
  • Page 46 V85 TT Characteristics ADDLE Pos. Description Type Quantity Torque Notes Self-locking nuts fixing the lumbar 2.5 Nm (1.84 lb ft) support Back side CHAR - 46...
  • Page 47 V85 TT Characteristics HOCK ABSORBER Pos. Description Type Quantity Torque Notes Rear shock absorber to gearbox fix- 50 Nm (36.88 lb ft) ing screw Rear shock absorber to frame fixing 50 Nm (36.88 lb ft) screw EAR BODYWORK Pos. Description...

  • Page 48: Nm (2.21 Lbf Ft)

    V85 TT Characteristics AILLIGHT Pos. Description Type Quantity Torque Notes Taillight to number plate holder fixing Self-tapping 3 Nm (2.21 lbf ft) screws 5x14 Rear direction indicator to number 3 Nm (2.21 lbf ft) With self-locking nut plate holder fixing screws Licence plate light to number plate 3 Nm (2.21 lbf ft)
  • Page 49 V85 TT Characteristics WINGARM Pos. Description Type Quantity Torque Notes Bellow to swingarm fixing screw 6 Nm (4.43 lbf ft) Swingarm pivot bolt fastening nut 50 Nm (36.88 lb ft) Swingarm fastening pin Screw until the end and unscrew by 1/4...
  • Page 50 V85 TT Characteristics EARBOX OMPONENTS Pos. Description Type Quantity Torque Notes Pinion fastening nut 100 Nm (73.76 lb ft) Loct. 648 + Nut re- bating on hollow pinion Oil drainage plug 30 Nm (22.13 lb ft) Oil load cap 25 Nm (18.44 lbf ft) Bleeder cap 10 Nm (7.38 lbf ft)
  • Page 51 V85 TT Characteristics EAR MUDGUARD Pos. Description Type Quantity Torque Notes Screws fastening the licence plate Self-tapping 3 Nm (2.21 lbf ft) holder fastener to the licence plate 3.9x14 holder Screws fastening the licence plate 8 Nm (5.90 lb ft)
  • Page 52 V85 TT Characteristics EAR BRAKE CALLIPER Pos. Description Type Quantity Torque Notes Screws fastening the rear brake cal- 25 Nm (18.44 lbf ft) liper to the calliper support bracket Pin fastening the rear brake calliper 35 Nm (25.81 lb ft)
  • Page 53 V85 TT Characteristics - E4 EAR WHEEL Pos. Description Type Quantity Torque Notes Rear wheel axle fastener nut M20x1.5 100 Nm (73.76 lb ft) - E5 EAR WHEEL Pos. Description Type Quantity Torque Notes Rear wheel axle fastener nut M20x1.5 100 Nm (73.76 lb ft)
  • Page 54 V85 TT Characteristics NDER SEAT COMPARTMENT Pos. Description Type Quantity Torque Notes Screw fastening the front brake pipe 6 Nm (4.43 lbf ft) feedthrough to the battery box Screws fastening the battery box to 6 Nm (4.43 lbf ft) the frame Screws fastening battery bracket/ 6 Nm (4.43 lbf ft)
  • Page 55 V85 TT Characteristics - E4 RONT ELECTRICAL SYSTEM Pos. Description Type Quantity Torque Notes Screws fastening the coil to the 10 Nm (7.38 lbf ft) frame Screws fastening the voltage regula- 10 Nm (7.38 lbf ft) tor to the frame Screw fastening the horn to the 25 Nm (7.38 lbf ft)
  • Page 56 V85 TT Characteristics - E4 ENTRAL ELECTRICAL SYSTEM Pos. Description Type Quantity Torque Notes Screw fastening the anti-rollover 6 Nm (4.43 lbf ft) sensor Screws fastening the left side wiring 6 Nm (4.43 lbf ft) harness support to the frame...
  • Page 57 V85 TT Characteristics - E5 ENTRAL ELECTRICAL SYSTEM Pos. Description Type Quantity Torque Notes Screw fastening the anti-rollover 6 Nm (4.43 lbf ft) sensor Screws fastening the left side wiring 4 Nm (2.95 lb ft) harness support to the frame...
  • Page 58 V85 TT Characteristics - E4 EAR ELECTRICAL SYSTEM Pos. Description Type Quantity Torque Notes Screws fastening the electronic ECU Self-tapping 3 Nm (2.21 lbf ft) support to the battery box Screw fastening the ABS sensor ca- 3 Nm (2.21 lbf ft)
  • Page 59 V85 TT Characteristics - E5 EAR ELECTRICAL SYSTEM Pos. Description Type Quantity Torque Notes Screws fastening the electronic ECU Self-tapping 3 Nm (2.21 lbf ft) support to the battery box Screw fastening the ABS sensor ca- 3 Nm (2.21 lbf ft)
  • Page 60 V85 TT Characteristics Pos. Description Type Quantity Torque Notes TEF fixing screws of lower centering M6x25 10 Nm (7.38 lbf ft) bracket (left) TEF fixing screws of lower centering M6x20 10 Nm (7.38 lbf ft) bracket (right) TCEI fixing screws of supports to lug- M6x25 10 Nm (7.38 lbf ft)
  • Page 61 INDEX OF TOPICS S-TOOLS PECIAL TOOLS...
  • Page 62 V85 TT Special tools SPECIAL TOOLS Stores code Description 020998Y Pinion case wrench 020999Y Crown counter- lock ring wrench GU19907000 Internal bearing ring extractor 021000Y Bevel gear set mounting 021003Y Bevel gear oil seal punch 021005Y Bevel gear cover oil seal punch...
  • Page 63 V85 TT Special tools Stores code Description 020978Y Cardan secondary oil seal mounting punch GU19927900 Punch for pressing the ring inside the bearing 020376Y Adaptor handle 020359S 42 x 47 mm punch 020360S 52 x 55 mm adaptor 001467Y036 Bearing internal cup extractor...
  • Page 64 V85 TT Special tools Stores code Description 020888S Pre-load tube clamp AP8140148 Plunger-spacer separator plate 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...
  • Page 65 V85 TT Special tools Stores code Description 021017Y OBD cable for E5 vehicles S-TOOLS - 65...
  • Page 66 INDEX OF TOPICS MAIN AINTENANCE...
  • Page 67 V85 TT Maintenance Scheduled maintenance table NOTE HALVE THE SERVICE INTERVALS INDICATED IF THE VEHICLE IS USED IN PARTICULARLY RAINY OR DUSTY CONDITIONS, ON POOR ROADS OR FOR HIGH PERFORMANCE RIDING. NOTE THE TIMES LISTED ON THE SCHEDULED MAINTENANCE TABLE INCLUDE TIME DEDICATED TO MANAGEMENT ACTIVITIES.
  • Page 68 V85 TT Maintenance Km x 1,000 (mi x 1,000) EVER EVER (0.9) (6.2) (12.4) (18.6) (24.9) (31.1) (37.3) Y 12 Y 24 MONT MONT Fuel pipes Labour time (minutes) NOTE AT EACH SCHEDULED MAINTENANCE MUST BE VERIFIED WITH THE DIAGNOSTIC TOOL IF THERE ARE ERRORS AND THE IF THE PARAMETERS ARE CORRECT.
  • Page 69 V85 TT Maintenance mi x 1.000 (km x 1.000) 0.9 (1,5) 6.2 (10) 12.4 18.6 24.9 31.1 37.3 (20) (30) (40) (50) (60) Nut/bolt tightness Suspensions and stability Head cover fastening screws dampers Filter box drain plug Brake lines Fuel pipes...
  • Page 70 V85 TT Maintenance Km x 1,000 (mi x 1,000) 1,5 (0.9) 10 (6.2) 20 (12.4) 30 (18.6) 40 (24.9) 50 (31.1) 60 (37.3) Tyres - pressure / wear (2) Clutch clearance adjustment Transmission oil filler plug washer Nut/bolt tightness Suspensions and stability...
  • Page 71 V85 TT Maintenance Spark plug • Unscrew and remove the screws (1) • Remove the cover (2). • Disconnect the spark plug cap (3) • Unscrew the spark plug (4) and re- move it Transmission fluid MAIN - 71...
  • Page 72 V85 TT Maintenance Replacement CAUTION THE UNIT MUST BE HOT WHEN THE OIL IS CHANGED AS UNDER SUCH CONDITIONS OIL IS FLUID AND THEREFORE EASY TO DRAIN. NOTE RIDE SOME km (miles) TO WARM UP ENGINE OIL • Place a recipient with a capacity of at least 400 cc (25 cu.in) under the drain...
  • Page 73 V85 TT Maintenance CAUTION IF IT IS NECESSARY TO INSTALL A NEW TRANSMISSION GEARBOX, PAY SPECIAL ATTEN- TION TO THE PROCEDURE BELOW Since they are already run-in at the factory, the complete transmission boxes coming from the Spare parts department contain a minimum residual oil quantity and therefore after installing them on the vehicle, the following procedure must be performed: •...
  • Page 74 V85 TT Maintenance Replacement NOTE HOT OIL IS MORE FLUID AND WILL DRAIN OUT MORE EASILY AND COMPLETELY. • Remove the sump guard • Place a collection container of suitable capacity under the drain plug (1) • Unscrew and remove the drain plug (1) NOTE WHILE REFITTING, USE A NEW SEAL WASHER.
  • Page 75 V85 TT Maintenance Engine oil filter • Undo the two screws (1) and remove the cover (2) • Remove the engine oil filter (3) • Spread a thin layer of oil on the sealing ring of the new engine oil filter •...
  • Page 76 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. CAUTION CHECK THE O-RING PRESENT ON THE FILLING CAP AND REPLACE IF DAMAGED.
  • Page 77 V85 TT Maintenance • 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 78 V85 TT Maintenance • Remove the spark plug cover • Remove the spark plug tube • Remove the three head cover fixing screws CAUTION CHECK THE DAMPENING RUBBER GASKETS ON THE BIG END COVER AND REPLACE THEM IF DAMAGED. •...
  • Page 79 V85 TT Maintenance • 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 • Intercept the top dead centre checking...
  • Page 80 V85 TT Maintenance Level check FRONT BRAKE • Rest the vehicle on its stand. • Turn the handlebar so that the fluid is at the same level as the plug. • Make sure that the fluid level in the res- ervoir is above the "MIN"...
  • Page 81 V85 TT Maintenance Top-up FRONT BRAKE • Unscrew and remove the screws (1) • Remove the cover (2). • Remove the diaphragm (3) and the gasket (4) • Top up MAIN - 81...
  • Page 82 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 83 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 84 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 85 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 VERTICAL ALIGNMENT OF THE BEAM IS CORRECT.
  • Page 86 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 87 V85 TT Electrical system Components arrangement Key: 1. Engine control unit 2. Secondary fuses 3. Main fuses ELE SYS - 87...
  • Page 88 V85 TT Electrical system 4. Battery 5. Coils 6. Front right turn indicator 7. Horn 8. Voltage regulator 9. Front speed sensor 10.Right Lambda probe 11.Oil pressure sensor 12.Right injector 13.Stop switch 14.Rear right turn indicator 15.Taillight 16.Front left turn indicator 17.Instrument cluster...
  • Page 89 V85 TT Electrical system • 1 x Taillight wiring • 1 x Fuel pump wiring • 1 x Left cylinder HV wire • 1 x Right cylinder HV wire • 1 x Fog light wiring (not standard) Consumable such as cable clamps, cable fasteners or cable grommets are indicated in the images...
  • Page 90 V85 TT Electrical system • Check that the positive cable is fastened correctly to the starter motor and that cap is fitted correctly CAUTION THE ENCIRCLED CONNECTORS ARE CONSIDERED CRITICAL IN COMPARISON WITH ANY OTHER BECAUSE THE VEHICLE WILL STOP OR PRESENT A MALFUNCTION IF THEY ARE AC- CIDENTALLY DISCONNECTED.
  • Page 91 V85 TT Electrical system 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. Medium sized clamp TABLE G - PRELIMINARY PHASE 1.
  • Page 92 V85 TT Electrical system TABLE H - PRELIMINARY PHASE • Arrange the wiring as illustrated in the figure TABLE I - PRELIMINARY PHASE • Arrange the wiring as illustrated in the figure TABLE J - PRELIMINARY PHASE • Arrange the wiring as illustrated in the...
  • Page 93 V85 TT Electrical system 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. Medium clamps (pre-mounted for subse- quent flywheel cables fastening)
  • Page 94 V85 TT Electrical system 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. Gear in neutral switch TABLE R - ASSEMBLY OF FRAME UNIT TO ENGINE 1.
  • Page 95 V85 TT Electrical system TABLE T - ASSEMBLY OF FRAME UNIT TO EN- GINE 1. Fall sensor 2. Fuel pump Pass the fall sensor and fuel pump outputs under the frame bracket as illustrated in the figure TABLE U - ASSEMBLY OF FRAME UNIT TO ENGINE 1.
  • Page 96 V85 TT Electrical system TABLE A2 - VOLTAGE REGULATOR ASSEM- 1. Horn connectors 2. Horn TABLE A3 - VOLTAGE REGULATOR ASSEM- • Position the excess cable as illustrated in the figure TABLE A4 - VOLTAGE REGULATOR ASSEM- 1. Voltage regulator...
  • Page 97 V85 TT Electrical system TABLE B1 - INSTRUMENT CLUSTER PRE-AS- SEMBLY AND ASSEMBLY ON THE BIKE 1. Plug socket with rubber piece 2. Air temperature sensor Assemble the turn indicators and run the wiring in the frame pipes TABLE B2 - INSTRUMENT CLUSTER PRE-AS- SEMBLY AND ASSEMBLY ON THE BIKE 1.
  • Page 98 V85 TT Electrical system TABLE B5 - INSTRUMENT CLUSTER PRE-AS- SEMBLY AND ASSEMBLY ON THE BIKE 1. Front right turn indicator connector 2. Front left turn indicator connector Run the connections in the instrument cluster head TABLE B6 - INSTRUMENT CLUSTER PRE-AS- SEMBLY AND ASSEMBLY ON THE BIKE 1.
  • Page 99 V85 TT Electrical system TABLE C - FRONT TURN INDICATORS 1. Right turn indicator connection During installation one wire must be covered and the other with sheath TABLE C1 - FRONT TURN INDICATORS 1. Left turn indicator connection During installation one wire must be covered and...
  • Page 100 V85 TT Electrical system TABLE D1 - HANDLEBAR 1. Front stop switch TABLE D2 - HANDLEBAR 1. Right light switch TABLE D3 - HANDLEBAR 1. Left light switch TABLE D4 - HANDLEBAR 1. Clutch switch ELE SYS - 100...
  • Page 101 V85 TT Electrical system 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. Cable gland TABLE E3 - FRONT WHEEL SPEED SENSOR 1.
  • Page 102 V85 TT Electrical system TABLE E4 - FRONT WHEEL SPEED SENSOR 1. Speed sensor cable TABLE E5 - FRONT WHEEL SPEED SENSOR 1. Speed sensor cable TABLE F - RH CONNECTOR POCKET 1. Small clamp 2. Large clamp 3. Medium sized clamp TABLE G - LH CONNECTOR POCKET 1.
  • Page 103 V85 TT Electrical system TABLE H - PREPARATION OF ELECTRICAL COMPONENTS TO BE MOUNTED ON THE LIGHT SWITCHES 1. Key connectors (no sign) TABLE H1 - PREPARATION OF ELECTRICAL COMPONENTS TO BE MOUNTED ON THE LIGHT SWITCHES 1. Speed sensor connector Perform a mark at 100 mm (3.94 in) from the con-...
  • Page 104 V85 TT Electrical system TABLE H4 - PREPARATION OF ELECTRICAL COMPONENTS TO BE MOUNTED ON THE LIGHT SWITCHES 1. Front stop switch Perform a mark at 100 mm (3.94 in) from the con- nector TABLE H5 - PREPARATION OF ELECTRICAL...
  • Page 105 V85 TT Electrical system TABLE I2 - OBJECTIFICATION OF THE ELEC- TRIC COMPONENTS ON THE RIGHT BOX 1. Clip End result after mounting the right side protection TABLE J - OBJECTIFICATION OF THE ELEC- TRIC COMPONENTS ON THE LEFT BOX 1.
  • Page 106 V85 TT Electrical system TABLE J3 - OBJECTIFICATION OF THE ELEC- TRIC COMPONENTS ON THE LEFT BOX • Proceed as indicated in the figure End result after mounting the left side protection TABLE K - FOG LIGHTS • After having first installed the fog light...
  • Page 107 V85 TT Electrical system TABLE K2 - FOG LIGHTS • Place the "L280" clamp on the junction box. TABLE K3 - FOG LIGHTS • Pass and place the cable harness as indicated. ELE SYS - 107...
  • Page 108 V85 TT Electrical system TABLE K4 - FOG LIGHTS • Fasten the left side junction box with the three screws, aligning the position- ing bolt on the hole of the box and then connect the fog light wiring harness to the vehicle's connector.
  • Page 109 V85 TT Electrical system TABLE K6 - FOG LIGHTS • After having assembled the relay with the rubber gasket, pass the connectors of the headlight and of the fog lights as indicated. • Connect the fog light connectors and the relay to the specific connectors of the wiring harness.
  • Page 110 V85 TT Electrical system TABLE M - OBJECTIFICATION OF THE PICK UP CONNECTOR • Fasten the Pick Up wiring harness con- nector to the flywheel' s cables using a small clamp, as shown in the figure NOTE ONLY FOR E5 VEHICLES...
  • Page 111 V85 TT Electrical system TABLE B - FILTER BOX AND THROTTLE BODY CONNECTIONS 1. Throttle valve cable TABLE B1 - FILTER BOX AND THROTTLE BODY CONNECTIONS 1. Fastener clip TABLE B2 - FILTER BOX AND THROTTLE BODY CONNECTIONS • Pull the following cable to the outside...
  • Page 112 V85 TT Electrical system TABLE C - SIDE STAND SWITCH AND COR- RECT ASSEMBLY ON THE VEHICLE • Overall view of pre-assembly TABLE C1 - SIDE STAND SWITCH AND COR- RECT ASSEMBLY ON THE VEHICLE 1. Fastener clip TABLE C2 - STAND SWITCH AND CORRECT ASSEMBLY ON THE VEHICLE 1.
  • Page 113 V85 TT Electrical system TABLE C4 - STAND SWITCH AND CORRECT ASSEMBLY ON THE VEHICLE 1. Side stand cabling TABLE C5 - STAND SWITCH AND CORRECT ASSEMBLY ON THE VEHICLE • Place the wiring harness in the specific guide, as illustrated in the figure...
  • Page 114 V85 TT Electrical system TABLE D1 - BRAKE LIGHT SWITCH AND COR- RECT ASSEMBLY ON THE VEHICLE 1. Brake light switch support TABLE D2 - BRAKE LIGHT SWITCH AND COR- RECT ASSEMBLY ON THE VEHICLE 1. Gearbox in neutral switch connection (mounted on support) 2.
  • Page 115 V85 TT Electrical system TABLE E1 - HIGH VOLTAGE CABLES 1. Left cylinder cable guide TABLE E2 - HIGH VOLTAGE CABLES 1. Left cylinder coil connector H.V. cable route to the left cylinder coil TABLE E3 - HIGH VOLTAGE CABLES 1.
  • Page 116 V85 TT Electrical system TABLE E5 - HIGH VOLTAGE CABLES • Proceed as indicated in the figure Overall view of how the two H.V. cables look with the respective cable guides indicated in the figure TABLE E6 - HIGH VOLTAGE CABLES 1.
  • Page 117 V85 TT Electrical system FIGURE G - STARTER MOTOR 1. Start relay cable FIGURE G1 - STARTER MOTOR 1. Power cable Fasten the power cable to the clamp with nut and washer and cover everything with the specific black cap FIGURE G2 - STARTER MOTOR 1.
  • Page 118 V85 TT Electrical system TABLE H - EARTH POINT ON ENGINE 1. Earth cable TABLE H1 - EARTH POINT ON ENGINE 1. Earth cable 2. Nut Fasten everything as illustrated in the figure TABLE I - RIGHT SIDE PANEL 1. Rear switch connector 2.
  • Page 119 V85 TT Electrical system TABLE J - LH FAIRING 1. Side stand connector 2. Rear abs sensor connector with clip TABLE J1 - LH FAIRING 1. Small clamp Fasten the support for the electrical parts and, us- ing the clamps (1) fasten the antitheft device and...
  • Page 120 V85 TT Electrical system TABLE K2 - RH LAMBDA PROBE (E5 VEHI- CLES) 1. Right Lambda probe TABLE K3 - RH LAMBDA PROBE (E5 VEHI- CLES) 1. Right Lambda probe connector TABLE L - LEFT LAMBDA PROBE 1. LH oxygen sensor...
  • Page 121 V85 TT Electrical system TABLE L1 - LEFT LAMBDA PROBE 1. Left lambda probe connector 2. Support for AMP connection 3. Voltage regulator support bracket TABLE L2 - LH LAMBDA PROBE (E5 VEHI- CLES) 1. LH oxygen sensor TABLE L3 - LH LAMBDA PROBE (E5 VEHI- CLES) 1.
  • Page 122 V85 TT Electrical system TABLE M1 - OIL PRESSURE BULB 1. oil pressure bulb eyelet Real view TABLE M2 - OIL PRESSURE BULB 1. oil pressure bulb eyelet 2. Washer The washer must be under the eyelet TABLE M3 - OIL PRESSURE BULB 1.
  • Page 123 V85 TT Electrical system TABLE N1 - CURRENT OUTLET ASSEMBLY (ACCESSORY) 1. Battery cover Remove the cover (1). TABLE N2 - CURRENT OUTLET ASSEMBLY (ACCESSORY) 1. USB cable gland TABLE N3 - CURRENT OUTLET ASSEMBLY (ACCESSORY) • Proceed as indicated in the figure...
  • Page 124 V85 TT Electrical system TABLE N5 - CURRENT OUTLET ASSEMBLY (ACCESSORY) • Proceed as indicated in the figure Remove the plug of the provision and USB port connector TABLE N6 - CURRENT OUTLET ASSEMBLY (ACCESSORY) • Proceed as indicated in the figure...
  • Page 125 V85 TT Electrical system TABLE O1 - ASSEMBLY OF THE FUEL PUMP WIRING HARNESS ON THE TANK 1. Fuel pump connector Connector fixed in the correct position on the sup- port for AMP connection TABLE O2 - ASSEMBLY OF THE FUEL PUMP WIRING HARNESS ON THE TANK 1.
  • Page 126 V85 TT Electrical system TABLE Q - ENGINE HEAD TEMPERATURE BULB • Pass the wiring harness of the temper- ature bulb over the intake manifold NOTE ONLY FOR E5 VEHICLES TABLE Q1 - ENGINE HEAD TEMPERATURE BULB 1. Engine head temperature bulb...
  • Page 127 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 128 V85 TT Electrical system TABLE A2 - WIRING ON THE SEAT PILLAR 1. Engine control unit • Connect the ECU connectors to the engine ECU (1) and engage it in the specific plastic base. The connectors are well engaged if the locking lever makes a "CLICK"...
  • Page 129 V85 TT Electrical system TABLE A5 - WIRING ON THE SEAT PILLAR 1. USB 2 power socket predisposition 2. Main fuses 3. Battery cover (mounted) Fasten the USB2 power socket predisposition in the specific support and the main fuses as illus-...
  • Page 130 V85 TT Electrical system TABLE B1 - COMPLETE TAILLIGHT AND LI- CENCE PLATE HOLDER (PRE-ASSEMBLY) 1. Taillight wiring harness 2. Grey reference for positioning TABLE B2 - COMPLETE TAILLIGHT AND LI- CENCE PLATE HOLDER (PRE-ASSEMBLY) 1. Fastening clip 2. Grey reference for positioning...
  • Page 131 V85 TT Electrical system TABLE B5 - COMPLETE TAILLIGHT AND LI- CENCE PLATE HOLDER (PRE-ASSEMBLY) 1. Fastener clip 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...
  • Page 132 V85 TT Electrical system TABLE C1 - REAR WHEEL SPEED SENSOR 1. Clip 2. Cable gland TABLE C2 - REAR WHEEL SPEED SENSOR 1. Small clamp 2. Speed sensor connector Connection of the speed sensor is fastened with a clip...
  • Page 133 V85 TT Electrical system Key: 1. Multiple connectors 2. - 3. - 4. - 5. USB power sockets (not standard) 6. Left light switch ELE SYS - 133...
  • Page 134 V85 TT Electrical system 7. Horn 8. air temperature sensor 9. Predisp. GMP/Tyre pressure 10.Instrument cluster 11.Heated hand grips (not standard) 12.Derating Temp. Sens. 13.Right light switch 14.Frt. brake switch. 15.Rear brake switch 16.Clutch switch 17.Ignition switch 18.Immobilizer antenna 19.Right rear turn indicator 20.Taillight...
  • Page 135 V85 TT Electrical system 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 57.Position lights and DRL 58.High beam LED module...
  • Page 136 V85 TT Electrical system Key: 1. Multiple connectors 2. Left light switch 3. Horn 4. USB power socket (not standard) 5. Instrument cluster 6. Heated hand grips (not standard) ELE SYS - 136...
  • Page 137 V85 TT Electrical system 7. Right light switch 8. Canister control (PURGE valve) 9. Rear brake switch 10.Clutch switch 11.Ignition switch 12.Immobilizer antenna 13.Right rear turn indicator 14.Taillight 15.Left rear turn indicator 16.Licence plate light 17.Anti-theft system (not standard) 18.Antitheft system LED 19.Front ABS sensor...
  • Page 138 V85 TT Electrical system 45.Lambda probe 1 (left) 46.Right cylinder injector 47.Left cylinder injector 48.Right cylinder coil 49.Left cylinder coil 50.T-Map sensor 51.Motorised throttle valve 52.Derating temperature sensor 53.Engine temperature sensor 54.Engine speed sensor 55.11MP ECU 56.EMI filter 57.Left fog light (not standard) 58.Left turn indicator...
  • Page 139 V85 TT Electrical system THE SECTIONS RELATIVE TO THE ELECTRICAL SYSTEM CONTAIN DRAWINGS OF CONNEC- TORS; NOTE THAT THE DRAWING ALWAYS DEPICT THE CONNECTOR/COMPONENT VIEWED FROM THE WIRING HARNESS SIDE, I.E. FROM THE SIDE ON WHICH THE CABLES LEADING FROM THE MAIN WIRING HARNESS ENTER THE CONNECTOR/COMPONENT.
  • Page 140 V85 TT Electrical system Purpose of check: the purpose of this check is to verify that a cable or circuit is correctly connected to the ground (-) of the vehicle. Tester: set the tester selector to the "continuity" symbol and place one of the tester probes on the vehicle ground point (or on the battery negative pole) and the other probe on the cable under inspection.
  • Page 141 V85 TT Electrical system nals are not loose, open/bent, etc.). For connec- tors whose terminals are not visible (e.g. Marelli control unit) use a metal cable of suitable diameter and introduce it carefully in the connector slot at the same depth as for the other terminals of the connector.
  • Page 142 V85 TT Electrical system IN THE CASE OF SPORADIC FAULTS, MOVE OR WIGGLE THE RELATIVE WIRING HARNESS SLIGHTLY WHILE PERFORMING EACH OF THE CHECKS INDICATED FOR TROUBLESHOOT- ING. Immobiliser The vehicle is equipped with an electronic engine locking system that is automatically activated when the ignition key is removed.
  • Page 143 V85 TT Electrical system If there is an immobilizer failure at ignition, the dashboard requests you to enter a user code. If the code is entered correctly, the dashboard sig- nals the failure by displaying the word SERVICE and the red general warning light turns on.
  • Page 144 V85 TT Electrical system Code recovery (Code recovery) This function must be used should it be necessary to change the user code when the user no longer remembers the current code. Both keys stored in the vehicle memory are needed to access this function.
  • Page 145 V85 TT Electrical system • Occurs, when the transponder is working, but it is not within the recognised ones. Identification • General alarm warning light steadily on (red) and "ALARM IMMO B0003" indication on the display Troubleshooting • Store the new key...
  • Page 146 V85 TT Electrical system • General alarm warning light steadily on (red) and "ALARM IMMO B0006" indication on the display Troubleshooting • Replace the instrument panel Error code B0007 (ALARM 1 KEY STORED) Error cause • Occurs when the number of stored keys is less than two Identification •...
  • Page 147 V85 TT Electrical system • Enter the USER CODE to continue. • If the code entered is correct, the first key is stored. • At this point, on the digital display of the motorcycle, after the automatic restart of the dynamic presentation screen, a...
  • Page 148 V85 TT Electrical system Dashboard Function: Its function is to display the parameters and any alarms / errors during the vehicle use Level in electrical circuit diagram: Instrument cluster Location: On the front part of the motorcycle, fixed to the support connected to the support frame.
  • Page 149 V85 TT Electrical system PARAMETERS AND STATES P.A.D.S. CHARACTERISTIC VALUE/ MEASUR NOTES EXAMPLE EMENT UNIT Number of stored keys Up to a maximum 4 keys total equivalent km Total number of equivalent km travelled by the vehicle. This counter CANNOT BE RESET...
  • Page 150 V85 TT Electrical system ACTIVATIONS AND ADJUSTMENTS SCREEN On this screen, you can delete the errors from the memory of the controller and you can enable some systems controlled by the control unit. ACTIVATIONS P.A.D.S. CHARACTERISTIC VALUE/ MEASUR NOTES EXAMPLE...
  • Page 151 V85 TT Electrical system Start-up system check Function Communicates to the control unit the will to start- up the engine. Operation / Operating principle Press the start-up button to close the specific cir- cuit taking the PIN 58 of the control unit to a voltage equal to zero (ground closing).
  • Page 152 V85 TT Electrical system • signal not plausible. Error cause • Fault in the switch (lock) of the engine start-up. A continuous voltage close to 0 was detected for a certain time (e.g. locked button). • The instrument panel does not indicate the presence of this error even in the ATT status.
  • Page 153 V85 TT Electrical system Specification Desc./Quantity D) 7.5A fuse Instrument cluster power supply, antitheft device power supply, hand grips and turn indicators E) 15A fuse ECU live positive lead F) 7.5A fuse ECU permanent positive lead G) 15A fuse Coils, secondary air injectors, fuel pump H) 7.5A fuse...
  • Page 154 V85 TT Electrical system Specification Desc./Quantity L) spare fuses They are located under the saddle on the right side Control unit REMOVAL • Remove the saddle • Unscrew and remove the screws (1) • Disconnect the connectors (2) • Remove the ECU (3)
  • Page 155 V85 TT Electrical system Function It manages the Ride by wire system, the injection/ ignition, the system safety checks and the self-di- agnosis function Level in electrical circuit diagram: Each level in which the main component involves the control unit Location: •...
  • Page 156 V85 TT Electrical system NOTE THIS ERROR GENERATES THE RECOVERY STATUS AND ENGINE SHUT-DOWN. P060B A/D converter Electrical diagnosis: • Circuit not functioning Error cause: • Replace the injection control unit. The instrument panel indicates this error by lighting up in a fixed manner the MI warning light and by flashing the general warning light.
  • Page 157 V85 TT Electrical system • Perform the troubleshooting for the other detected errors P1650 Engine events configuration Checksum calculation error Error cause: • Corrupt Flash-eeprom (hardware problem). • Upload (e.g. in service) of an incompatible software version, therefore missing the reference check-sum.
  • Page 158 V85 TT Electrical system PAY ATTENTION TO THE POSITIVE BATTERY CABLE, WHICH MUST PASS BELOW THE UPPER PART OF THE FRAME. CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN- NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
  • Page 159 V85 TT Electrical system Speed sensor VEHICLE ABS SENSOR Function: Generates a signal used by the ABS control unit to determine the speed value of the wheel. Operation / Operating principle: Magneto-resistive sensor: generation of a square wave having an amplitude of approximately 1V •...
  • Page 160 V85 TT Electrical system P0501 Front wheel speed sensor/signal • Connect to the ABS control unit diagnostic. P2158 Rear wheel speed sensor/signal • Connect to the ABS control unit diagnostic. 5D90 Front speed sensor - electrical fault Error cause •...
  • Page 161 V85 TT Electrical system • Faulty sensor or missing sensor/tone wheel. Or excessive distance between the sensor and the tone wheel or tone wheel with wrong number of teeth Troubleshooting • Check that the speed sensor and the tone wheel are installed; If they are not, install them.
  • Page 162 V85 TT Electrical system wiring harness. If OK, replace the control unit. If PIN 2 has approx. 12 V, check the continuity of the yellow cable between PIN 1 of the sensor on the wiring harness side and PIN 15 of the ABS control unit connector;if not OK, restore the wiring harness;...
  • Page 163 V85 TT Electrical system wheel has the correct number of teeth or if it is dirty, deformed or wrongly fixed; if it is not OK, replace the tone wheel; if it is OK, replace the speed sensor 5DA5 Rear speed sensor - wheel speed too high or too low functional fault Error cause •...
  • Page 164 V85 TT Electrical system 3. shielding with ground connection (blue/ green cable) CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN- NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
  • Page 165 V85 TT Electrical system Level in electrical circuit diagram: intake air pressure sensor Location: • on the vehicle: under the tank, left side. • connector: on the sensor. Electrical specifications: - Pin out: 1. Ground 2. Temperature signal 3. Power supply 5V 4.
  • Page 166 V85 TT Electrical system if not ok turn the key to OFF and check continuity between PIN 51 of the control unit con- nector and PIN 3 of the sensor connector: if not OK, restore the wiring harness; if OK, replace the control unit;...
  • Page 167 V85 TT Electrical system • If short circuit to negative, check the correct resistance of the sensor: if resistance = 0, replace the sensor; if the resistance is correct, it means that the purple/black cable has ground connection: restore the cable harness Error due to unexpected air intake into the cylinders manifold P1600 •...
  • Page 168 V85 TT Electrical system Engine temperature sensor OIL TEMPERATURE SENSOR Function It is used to communicate the engine temperature to the control unit in order to optimise its operation. Operation / Operating principle NTC type sensor (resistance sensor, inversely variable with temperature).
  • Page 169 V85 TT Electrical system • If open circuit, short circuit to positive: excessive voltage has been detected at PIN 72 of the VEHICLE connector. • If short circuit to negative: equal voltage detected at PIN 72 of the VEHICLE connector.
  • Page 170 V85 TT Electrical system NGINE TEMPERATURE SENSOR RESISTANCE Specification Desc./Quantity Resistance at -40 °C (-40 °F) 100.950 kOhm Resistance at -30 °C (-22 °F) 53.100 kOhm Resistance at -20 °C (-4 °F) 29.120 kOhm Resistance at -10 °C (14 °F) 16.600 kOhm...
  • Page 171 V85 TT Electrical system 1 of the sensor. If the air temperature sensor is also displayed at the same time, this means that the short circuit to positive is present in the grey cable shared by the two sensors. •...
  • Page 172 V85 TT Electrical system • connector: on the right front side, fas- tened to the regulator support bracket Electrical specifications • Heating circuit: 7-9Ω at ambient temp. Left lambda pin out (1): 1. Sensor signal + (grey wire) 2. Sensor signal - (green/grey wire) 3.
  • Page 173 V85 TT Electrical system • If the probe connector is disconnected (voltage almost equal to zero) it switches to the state of low Fault Left/right cylinder ratio control • Open loop - Closed loop - Half closed loop - Low/half cl. loop •...
  • Page 174 V85 TT Electrical system • Check the sensor connector PIN 1 ground insulation. If there is no insulation, restore the wiring harness. • Check the sensor connector PIN 2 ground insulation. If there is no insulation, restore the wiring harness.
  • Page 175 V85 TT Electrical system • Short-circuit to positive: an excessive voltage was detected at PIN 32 of the ENGINE con- nector. • If open circuit, short circuit to negative: a voltage equal to zero was detected at PIN 32 of the ENGINE connector.
  • Page 176 V85 TT Electrical system • Check the continuity of the circuit from the probe connector (PIN 1 and PIN 2) towards the probe: replace the lambda probe if there is no continuity; if there is continuity, check the sensor connector and the Marelli control unit connector: if NOT OK, restore; if OK, check the continuity between the ENGINE connector PIN 10 and PIN 22 and restore the wiring harness.
  • Page 177 V85 TT Electrical system • no switching from high / no switching from low Error cause: • If no switching from high: is shown when the ratio control is in closed loop and when the secondary air valve is not operating. The error is validated if the engine is in CUTOFF status and the probe signal is close to 1V, or if the engine is in another operating condition that requires the injection but the switching from the"HIGH RATIO"...
  • Page 178 V85 TT Electrical system the sensor connector and for the Marelli control unit connector: if NOT OK restore; if OK, with the key ON and the sensor connector disconnected, check if there is battery voltage at PIN 4: if NOT OK, check the continuity of the Red//Brown cable between the probe connector and the injection relay (no.
  • Page 179 V85 TT Electrical system • On the RH intake manifold • Connector: on injector Electrical specifications • 14.8 Ohm +/- 5% (at ambient temper- ature) Pin out LH injector: 1. 12 V power supply (orange/green) 2. Ground (grey/red) Pin out RH injector: 1.
  • Page 180 V85 TT Electrical system • Short-circuit to positive: excessive voltage has been detected on VEHICLE PIN 67. If short circuit to negative: no voltage has been detected. If open circuit: an interruption has been detected Troubleshooting • Short-circuit to positive: disconnect the injector connector, set key to ON, activate the com- ponent with the diagnostic tool and check if there is voltage on the white/black cable on the injector connector: if there is voltage, restore the filter box cable harness.
  • Page 181 V85 TT Electrical system 4. Fuel level sensor positive signal 5. 12V power supply PETROL SENSOR Error code B0012 (PETROL SENSOR ERROR) • The petrol sensor is disconnected. Identification • Reserve warning light flashing. Troubleshooting Check the connectors of the instrument panel and the sensor. Check the integrity and continuity of the wiring harnesses: •...
  • Page 182 V85 TT Electrical system Coil Function Spark generation Operation / Operating principle With inductive discharge Level in electrical circuit diagram: coils and injectors Location: • connector: under the tank, close to the canister filter • sensor: front side of the vehicle, fas-...
  • Page 183 V85 TT Electrical system • If open circuit, short circuit to negative: check the electrical characteristics of the coil: if not ok, replace the coil; if ok, perform the check procedure for the coil connector and for the Marelli control unit connector; if not ok restore; if everything is ok, check the continuity of the cable between the two ends of the cable: if there is no continuity, restore the wiring harness;...
  • Page 184 V85 TT Electrical system • on the vehicle: under the tank • connector: on the throttle body Pin out: 1. potentiometer signal 1 (yellow/black cable) 2. power supply voltage + 5 V (orange/white cable) 3. throttle drive command (+) (yellow/white ca- ble) 4.
  • Page 185 V85 TT Electrical system BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROU- BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. DIAGNOSTIC TOOL: STATES Automatic throttle valve self-learning •...
  • Page 186 V85 TT Electrical system • Check the Throttle Valve Potentiometer 1 parameter (voltage) to understand which signal the control unit receives. Check the throttle body connector and the control unit connector. Check that the resistance of the cable between the throttle body connector PIN 1 and the control unit PIN 48 is a few tenths of ohm.
  • Page 187 V85 TT Electrical system • The throttle valve mechanical control could be damaged Troubleshooting • Replace the throttle body Throttle valve Limp Home self-learning P1400 • Test failed Error cause • Position of the throttle valve, maintained by the springs, outside the specified range (at each key ON).
  • Page 188 V85 TT Electrical system • in conditions of low ambient temperature and engine temperature, a correct throttle valve rotation was not detected: possible presence of ice in the duct (at each key ON). The in- strument panel does not indicate the presence of this error even in the ATT status Troubleshooting •...
  • Page 189 V85 TT Electrical system • If short circuit to negative: disconnect the throttle body connector, turn the key ON and check if PIN 3 has continuity with the vehicle ground: if there is continuity restore the wiring harness, if there is no continuity replace the throttle body •...
  • Page 190 V85 TT Electrical system • Sensor: engine right side. • Connector: on the sensor. Electrical specifications • Engine off: closed circuit (continuity). • With engine started: open circuit (infin- ite resistance). Pin-out 1. Voltage 12V (violet). Oil pressure sensor error - B0001 Error cause •...
  • Page 191 V85 TT Electrical system Clutch lever sensor Function Indicates the clutch lever position to the control unit. Operation / Operating principle If a gear is engaged but the clutch is engaged, that is circuit closed to ground, there is consent to start the vehicle.
  • Page 192 V85 TT Electrical system ground of PIN 2 (Green/Pink cable): if there is no continuity, restore cable harness; if there is, replace the sensor. • Always pressed indication on the diagnostic tool: check the sensor connector and the control unit connector (special attention to PIN76): if not OK, restore cable harness; if OK, discon- nect both terminals from the sensor and check, with key set to ON, continuity to ground of PIN 2 (Green/Pink cable): if there is no continuity, restore cable harness;...
  • Page 193 V85 TT Electrical system Side stand sensor Function indicates to the control unit the position of the side stand Operation / Operating principle If the gear is engaged and the side stand is unfol- ded, and therefore the circuit is open, the control...
  • Page 194 V85 TT Electrical system • Indication on the diagnostic tool always up: disconnect the two ends from the sensor and check if, with the stand down, there is continuity between the two PINS: if there is continuity replace the sensor; if open circuit, it means that there is short circuit to ground of the brown/...
  • Page 195 V85 TT Electrical system • Short-circuit to positive: disconnect the component, set the key to ON, start the vehicle and check if the error symptom is still "shorted to positive": it means that short circuit is between black/white cable and a cable in voltage, therefore restore cable harness; if the error symp- tom is short circuit to ground, it means that short circuit is inside the valve and therefore, you must replace the component.
  • Page 196 V85 TT Electrical system Key: • (A) Brake pulled • (B) Brake released Error code B0203 (ERROR FRONT BRAKE ON THE LINE NORMALLY CLOSED) Troubleshooting Check the connectors of the instrument panel and the button. Check the integrity and continuity of the wiring harnesses: •...
  • Page 197 V85 TT Electrical system • (brake sensors errors) connect to the instrument panel diagnosis Error cause • Malfunction or communication interruption from the button on the light switch control. • Malfunction or breakage of the rear brake switch The presence of this error is signalled by the fixed lighting of the general warning light.
  • Page 198 V85 TT Electrical system • PIN 12 - Water temperature sensor in- • PIN 13 - B track handle input • PIN 14 - K serial line for diagnosis • PIN 15 - • PIN 16 - Power ground 2 •...
  • Page 199 V85 TT Electrical system • PIN 40 - Key input • PIN 41 - Output for throttle motor drive • PIN 42 - Key input • PIN 43 - Secondary air valve command output • PIN 44 - Lambda 2 heater command output •...
  • Page 200 V85 TT Electrical system • PIN 66 - L CAN line (high speed) • PIN 67 - Cylinder 2 injector command output • PIN 68 - • PIN 69 - Start-up relay command out- • PIN 70 - Side stand input •...
  • Page 201 V85 TT Electrical system • Engine temperature / - • Engine temperature before Recovery /- • Engine temperature at cranking / Engine temperature at start-up • Potentiometer A track hand grip position / Hand grip position potentiometer signal (track A) •...
  • Page 202 V85 TT Electrical system • Track 1 CF1 lower mechanical position / Throttle valve lower position • Vehicle speed / - • Coil 1 Dwell time / - • Coil 2 Dwell time / - • Number of ration engaged / Indicates the gear engaged •...
  • Page 203 V85 TT Electrical system • Map Down switch control state - Active / Inactive / Short circuit / Open circuit • Cruise and related switched state - ON / OFF / SET • Cruise and related switches state - Pressed / Not pressed •...
  • Page 204 V85 TT Electrical system Instrument cluster - Pin-out key: • PIN 1 - Left handgrip (brown) • PIN 2 - Aerial A (grey) • PIN 3 - Aerial B (grey) • PIN 4 - Petrol level (green/grey) • PIN 5 - Air temperature (pink) •...
  • Page 205 V85 TT Electrical system • PIN 31 - Fuel reserve (green/black) • PIN 32 - CAN L (cable X1) • PIN 33 - CAN H (cable X2) • PIN 34 - Sensor ground (blue/black) NOTE ONLY FOR E5 VEHICLES Instrument cluster - Pin-out key: •...
  • Page 206 V85 TT Electrical system • PIN 29 - Front left indicator (light blue/ black) • PIN 30 - Rear left indicator (light blue) • PIN 31 - Fuel reserve (green/black) • PIN 32 - CAN L (cable X1) • PIN 33 - CAN H (cable X2) •...
  • Page 207 V85 TT Electrical system • Code reset service / User code reset • Key reset service / Keys Reset • Odometer set service / Odometer coding ABS Modulator NOTE ONLY FOR E4 VEHICLES ABS ECU - Pin-out key: • PIN 1 - •...
  • Page 208 V85 TT Electrical system • PIN 10 - Ground • PIN 11 - CAN L line (low speed) • PIN 12 - • PIN 13 - • PIN 14 - • PIN 15 - Rear speed sensor ground • PIN 16 - •...
  • Page 209 V85 TT Electrical system • Replace the ABS control unit 5DF5 ABS control unit - Control unit internal hardware error Error cause • Possible control unit fault Troubleshooting • Replace the ABS control unit 5DF3 ABS control unit - Low electrical voltage / long detection period Error cause •...
  • Page 210 V85 TT Electrical system • Can line Function Allows communication between injection control unit, the instrument cluster, the ABS control unit, left light switch, GMP / tyre pressure set-up, OBD connector Operation / Operating principle A CAN line (Controller Area Network) is a connection between different electronic devices of a vehicle organised like a computer network (internet).
  • Page 211 V85 TT Electrical system • Between PIN 66 and 80 of the engine control unit • Between PIN 32 and 33 of the instrument panel • Between PIN 2 and 11 of the ABS control unit • Between PIN 3 and 4 of the left light switch •...
  • Page 212 V85 TT Electrical system • General alarm warning steadily on (red) and the "ALARM DISCONNECTED" message on the display Troubleshooting • Check that there is no continuity between the two cables of the CAN line; if not OK restore, if OK check the integrity and the continuity between PIN 32 instrument cluster and PIN 4 left light switch;...
  • Page 213 V85 TT Electrical system connector) with 1 connector disconnected at a time and turning the key to ON position: If not OK, restore; if OK, replace the Marelli control unit. NOTE THE PRESENCE OF THIS ERROR DETERMINE THE DEACTIVATION OF THE TRACTION CON- TROL AND THE CRUISE CONTROL.
  • Page 214 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 215 V85 TT Engine from vehicle Vehicle preparation CAUTION TO PERFORM THE MAINTENANCE OPERATIONS AND IF YOU NEED TO LIFT THE VEHICLE, USE A PANTOGRAPH LIFT LOCATED NEXT TO THE OIL SUMP. AVOID DAMAGING IT, FIRST REMOVE THE OIL SUMP GUARD EVERY TIME A PANTOGRAPH LIFT IS USED.
  • Page 216 V85 TT Engine from vehicle • Free the connector (2) from the wiring harness as illustrated in the figure • Disconnect the connector (3) • Unscrew and remove the screws (4) • Remove the left headstock cover (5) ENG VE - 216...
  • Page 217 V85 TT Engine from vehicle • Disconnect the connector (6) NOTE ONLY FOR E4 VEHICLES • Remove the clamp (7) NOTE ONLY FOR E4 VEHICLES • Unscrew and remove the screws (8) • Remove the connectors box (9) ENG VE - 217...
  • Page 218 V85 TT Engine from vehicle • Unscrew and remove the screws (10) • Remove the injector cover (11) • Undo and remove the screw (12) • Remove the left injector (13) ENG VE - 218...
  • Page 219 V85 TT Engine from vehicle • Remove the clamp (14) • 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 220 V85 TT Engine from vehicle • Remove the starter motor cover (18) • Lift the protective boot (19) • Unscrew the nut (20) and remove it. • Remove the cable (21) ENG VE - 220...
  • Page 221 V85 TT Engine from vehicle • Disconnect the connector (22) • Unscrew and remove the screws (23) • Remove the starter motor (24). • Disconnect the connector (25) ENG VE - 221...
  • Page 222 V85 TT Engine from vehicle • Unscrew the nut (26) and remove it. • Remove the cable (27) and (28) • Unscrew and remove the screw (29) • Remove the oil pressure bulb cover (30) • Unscrew and remove the screw (31) •...
  • Page 223 V85 TT Engine from vehicle • Press the lever (33) toward the front part of the vehicle, as illustrated in the figure, to eliminate the tension to which the clutch cable is subjected • Simultaneously slide out and remove the clutch cable (34) from the points in- dicated in the figure •...
  • Page 224 V85 TT Engine from vehicle • Disconnect the connector (35) located on the left side of the vehicle NOTE ONLY FOR E5 VEHICLES • Unscrew and remove the screws (36) • Remove the cover (37). • Disconnect the spark plug cap (38)
  • Page 225 V85 TT Engine from vehicle • Unscrew and remove the screws (39) • Remove the voltage regulator (40) from the frame and place it beside the vehicle • Unscrew and remove the screws (41) • Remove the voltage regulator support bracket (42) •...
  • Page 226 V85 TT Engine from vehicle • Disconnect the connector (43) • Unscrew and remove the screws (45) • Momentarily move the connectors box and remove the clamp (46) • Keeping the connectors box moved, remove the cable (47) from the chassis area •...
  • Page 227 V85 TT Engine from vehicle • Remove the pipe feedthrough (48) • Disconnect the secondary air pipes (49) • Blocking the pin (51) • Unscrew the nut (50) and remove it. • Remove the pin (51) • Unscrew and remove the screws (52) •...
  • Page 228 V85 TT Engine from vehicle • Retrieve the washer (54) • Retrieve the washer (55) • Secure the engine (56) so that is does not fall and then lift the vehicle's chas- sis using a hydraulic jack, so that it is...
  • Page 229 INDEX OF TOPICS NGINE...
  • Page 230 V85 TT Engine TO CONSULT THE CHAPTER ABOUT THE ENGINE AND ITS COMPONENTS PLEASE REFER TO THE APPROPRIATE MANUAL: "MSS Engine V85" ENG - 230...
  • Page 231 INDEX OF TOPICS P SUPP OWER SUPPLY...
  • Page 232 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 - 232...
  • Page 233 V85 TT Power supply Fuel pump UEL TANK Pos. Description Type Quantity Torque Notes Screws fastening the fuel tank to 10 Nm (7.38 lbf ft) frame Ring nut fastening the fuel pump to 20 Nm (14.75 lbf ft) the fuel tank Removing •...
  • Page 234 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 - 234...
  • Page 235 V85 TT Power supply FILTER REPLACEMENT • Remove the plastic clamp (A) securing the connector. • Disconnect the fuel gauge connector (B). • Remove the metal collar (C) from the corrugated pipe. • Remove the corrugated pipe (D) from the filter (E). During the operation, be careful not to damage the fuel level sensor.
  • Page 236 V85 TT Power supply • Unscrew the 2 screws (F) between the plastic head and the metallic bracket. • Disconnect the fuel pump connector (G) and release the wiring harness. • Remove the plastic head from the met- al bracket.
  • Page 237 V85 TT Power supply • Insert the spare kit in the correspond- ing seat and then reinsert the bracket in the head • Proceed by screwing the two screws (F) to lock the metal bracket to the head • Insert the metal collar (C) and then in-...
  • Page 238 V85 TT Power supply • Lock the connector in the indicated po- sition, using a plastic clamp and ar- range the cables as shown. PREFILTER REPLACEMENT • The prefilter can be replaced manually, without using tools. Place the prefilter with the an-...
  • Page 239 V85 TT Power supply Key: 1. Control unit position 2. Ignition switch 3. Battery 4. Fuel pump 5. Coils 6. Instrument cluster 7. air temperature sensor 8. Throttle valve position sensor 9. Injectors 10.Crankshaft position sensor 11.Engine temperature sensor 12.Lambda probe 13.Side stand switch...
  • Page 240 V85 TT Power supply E5 VEHICLES INJECTION SCHEME Key: 1. Control unit position 2. Ignition switch 3. Battery 4. Fuel pump 5. Coils 6. Instrument cluster 7. air temperature sensor 8. Throttle valve position sensor 9. Injectors 10.Crankshaft position sensor 11.Engine temperature sensor...
  • Page 241 V85 TT Power supply 13.Side stand switch 14.Gear sensor 15.fall sensor P SUPP - 241...
  • Page 242 INDEX OF TOPICS SUSP USPENSIONS...
  • Page 243 V85 TT Suspensions Handlebar ANDLEBAR ONTROLS Pos. Description Type Quantity Torque Notes Screws fastening the lower U-bolts to 50 Nm (36.88 lb ft) the upper steering yoke Screws fastening the lower U-bolt 25 Nm (18.44 lbf ft) clamp to the handlebar Screws fastening the handguards 10 Nm (7.38 lbf ft)
  • Page 244 V85 TT Suspensions Removing • Remove the rear view mirrors • Remove the handguards • Remove the front brake pump • Remove the clutch pump • Unscrew and remove the bushings (1) from both sides of the vehicle • Remove the left hand grip (2) •...
  • Page 245 V85 TT Suspensions • Loosen the two screws (5) • Unscrew and remove the screws (6) • Loosen the screw (7) • Remove the right-hand lights switch cover (8) • Loosen the screws (9) SUSP - 245...
  • Page 246 V85 TT Suspensions • Unscrew and remove the screws (10) • Remove the U-bolt (11) • 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...
  • Page 247 V85 TT Suspensions • Remove the handlebar (15) Front fork RONT FORK Pos. Description Type Quantity Torque Notes Screws fastening the calliper mount- 10 Nm (7.38 lbf ft) ing bracket to the wheel axle SUSP - 247...
  • Page 248 V85 TT Suspensions TEERING Pos. Description Type Quantity Torque Notes Ring nut fastening the lower plate/ First tightening tor- steering pivot assembly to the head- que 60 Nm (44.25 lb stock ft) - Second tighten- ing torque 30 Nm +/- 5 Nm (22.13 +/-...
  • Page 249 V85 TT Suspensions The following procedure is described for a single fork stanchion, but is valid for both stanchions. • Remove the front mudguard • Remove the front wheel • Loosen the screw (1) • Loosen the two screws (2) •...
  • Page 250 V85 TT Suspensions 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. • Unscrew the upper cap (1). Specific tooling AP8140149 Guard for assembly operations •...
  • Page 251 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 252 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 253 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 254 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 stan- chion several times in order to ensure the oil is drained completely.
  • Page 255 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 256 V85 TT Suspensions If the scratches are deep, replace the stanchion . Using a dial gauge, check than any bending of the stanchion is below the limit value. If it is over the limit, replace the stanchion . CAUTION A BENT STANCHION SHOULD NEVER BE STRAIGHTENED SINCE ITS STRUCTURE WOULD BE WEAKENED MAKING THE VEHICLE DANGEROUS TO USE.
  • Page 257 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 258 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 259 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 260 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 261 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 262 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 263 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. CAUTION CHECK THE O-RING PRESENT ON THE FILLING CAP AND REPLACE IF DAMAGED.
  • Page 264 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 265 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 266 V85 TT Suspensions Removal • Loosen the screws (1) from both sides of the steering yoke • Unscrew and remove the screws (2) • Remove the U-bolt (3) • Unscrew and remove the fastening bushing (4) • Undo and remove the screw (5) •...
  • Page 267 V85 TT Suspensions • Remove the steering yoke (6) Steering bottom yoke 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 268 V85 TT Suspensions • Remove the dust seal ring (4) • 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 SUSP - 268...
  • Page 269 V85 TT Suspensions TEERING Pos. Description Type Quantity Torque Notes Ring nut fastening the lower plate/ First tightening tor- steering pivot assembly to the head- que 60 Nm (44.25 lb stock ft) - Second tighten- ing torque 30 Nm +/- 5 Nm (22.13 +/-...
  • Page 270 V85 TT Suspensions • Adjust by tightening the lower ring nut to the prescribed torque • With the front wheel lifted off the ground, turn the steering all the way right and left three or four times • Check the tightening torque of the low-...
  • Page 271 V85 TT Suspensions • Using a generic bearing puller, remove the lower seat of the steering bearing as illustrated in the figure LOWER STEERING BEARING • Remove the lower steering bearing (4) • Remove the lower seat (5) of the lower steering bearing •...
  • Page 272 V85 TT Suspensions Assembling LOWER STEERING BEARING • Using the appropriate punch, insert the upper seat of the lower steering bear- ing in the point indicated in the figure • Insert the lower seat (1) of the lower steering bearing •...
  • Page 273 V85 TT Suspensions • Insert the upper steering bearing (3) • Insert the upper seat (4) of the upper steering bearing Shock absorbers HOCK ABSORBER Pos. Description Type Quantity Torque Notes Rear shock absorber to gearbox fix- 50 Nm (36.88 lb ft)
  • Page 274 V85 TT Suspensions Pos. Description Type Quantity Torque Notes Rear shock absorber to frame fixing 50 Nm (36.88 lb ft) screw Removing • Blocking the nut (1) • Undo and remove the screw (2) • Undo and remove the screw (3) •...
  • Page 275 INDEX OF TOPICS CHAS HASSIS...
  • Page 276 V85 TT Chassis CAUTION TO PERFORM THE MAINTENANCE OPERATIONS AND IF YOU NEED TO LIFT THE VEHICLE, USE A PANTOGRAPH LIFT LOCATED NEXT TO THE OIL SUMP. AVOID DAMAGING IT, FIRST REMOVE THE OIL SUMP GUARD EVERY TIME A PANTOGRAPH LIFT IS USED.
  • Page 277 V85 TT Chassis - E5 RONT WHEEL Pos. Description Type Quantity Torque Notes Nut fastening the front wheel axle M25x1.5 80 Nm (59.01 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 278 V85 TT Chassis • 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 • Unscrew and remove the screws (6) •...
  • Page 279 V85 TT Chassis • Loosen the screws (9) • Unscrew the nut (10) and remove it. • Retrieve the washer (11) • Remove the wheel axle (12) CHAS - 279...
  • Page 280 V85 TT Chassis • 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. • Remove the front wheel •...
  • Page 281 V85 TT Chassis • 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 282 V85 TT Chassis • Replace both wheel bearings. CHECKING RADIAL AND AXIAL PLAY • Check the radial and axial play. Axial play: minimal axial play is permitted. Radial: none. If one or both bearings do not fall within the control parameters: •...
  • Page 283 V85 TT Chassis ADJUST THE SPOKE TENSIONING IF THE SPOKES ARE SLOW AND THE RIM IS DEFORMED. Characteristic Maximum radial and axial eccentricity: 1 mm (0.039 in) Installing • Insert the spacer (1) • Place the front wheel (2) between the fork stanchions •...
  • Page 284 V85 TT Chassis • Insert the washer (4) • Insert and tighten the nut (5) • Tighten the screws (6) • Tighten the screws (7) CHAS - 284...
  • Page 285 V85 TT Chassis • Correctly place the right front brake calliper (8) • Insert and tighten the screws (9) • Correctly place the right front brake calliper (10) • Insert and tighten the screws (11) • Position the ABS sensor (12) on the calliper mounting bracket •...
  • Page 286 V85 TT Chassis • Insert the ABS sensor cable in the ca- ble glands (14) 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) •...
  • Page 287 V85 TT Chassis FRONT WHEEL BEARINGS INSTALLATION • Using an appropriate punch, install the wheel bearing as illustrated in the fig- • Insert the dust cover (1) • Rotate the wheel and repeat the entire operation from the opposite side of the...
  • Page 288 V85 TT Chassis - E5 EAR WHEEL Pos. Description Type Quantity Torque Notes Rear wheel axle fastener nut M20x1.5 100 Nm (73.76 lb ft) Rimozione • Undo and remove the screw (1) • Holding the pin (3) in place, unscrew...
  • Page 289 V85 TT Chassis • Retrieve the washer (4) • Remove the pin (3) • Remove the brake calliper support plate (5) from the brake disc, complete with rear brake calliper • Remove the rear wheel (6) CHAS - 289...
  • Page 290 V85 TT Chassis • Retrieve the bushing (7) FLEXIBLE COUPLING REMOVAL • Remove the rear wheel • Remove the flexible couplings (1) REMOVING THE REAR BRAKE DISC • Remove the rear wheel • Unscrew and remove the screws (1) •...
  • Page 291 V85 TT Chassis • Replace both wheel bearings. ALWAYS REPLACE BOTH BEARINGS. ALWAYS REPLACE THE BEARINGS WITH COMPONENTS OF THE SAME TYPE. • Check the radial and axial play. Axial play: minimal axial play is permitted. Radial: none. If one or both bearings do not fall within the control parameters: •...
  • Page 292 V85 TT Chassis Characteristic Maximum radial and axial eccentricity: 1 mm (0.039 in) FINAL DRIVE UNIT BEARINGS Carry out the check with the bearings fitted on the final drive unit. CHECKING ROTATION • Remove the left spacer. • Remove the right spacer.
  • Page 293 V85 TT Chassis ALWAYS REPLACE ALL THE FLEXIBLE COUPLINGS WITH OTHERS OF THE SAME TYPE. Installing • Place the spacer (1) on the rear wheel • Place the rear wheel (2) in the swing- • Correctly place the rear brake calliper (3), complete with support bracket •...
  • Page 294 V85 TT Chassis • Insert the washer (5) • Holding the pin (6) in place, tighten the nut (7) • Insert and tighten the screw (7) FLEXIBLE COUPLINGS INSTALLATION • Remove the rear wheel • Insert the flexible couplings (1) in the...
  • Page 295 V85 TT Chassis REAR BRAKE DISC INSTALLATION • Remove the rear wheel • Place the brake disc (1) • Place the phonic wheel (2) • Insert and tighten the screws (3) Swinging arm WINGARM Pos. Description Type Quantity Torque Notes Bellow to swingarm fixing screw 6 Nm (4.43 lbf ft)
  • Page 296 V85 TT Chassis Removing • Removing the clamp (1) • Unscrew the pin (2) and remove it. • Unscrew the nut (3) and remove it • Unscrew the pin (4) and remove it. NOTE DURING THE REASSEMBLY PHASE, AFTER HAVING TIGHTEN THE PIN MANUALLY, LOOSE IT 1/4 OF A TURN.
  • Page 297 V85 TT Chassis • Remove the swingarm (5) Cardan shaft 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)
  • Page 298 V85 TT Chassis In the figure are shown two worn toothing profiles: • Profile (3) shows acceptable wear, the cardan shaft should not be replaced. • Profile (4) shows unacceptable wear, the cardan shaft must be replaced. Bevel gears EARBOX Pos.
  • Page 299 V85 TT Chassis EARBOX OMPONENTS Pos. Description Type Quantity Torque Notes Pinion fastening nut 100 Nm (73.76 lb ft) Loct. 648 + Nut re- bating on hollow pinion Oil drainage plug 30 Nm (22.13 lb ft) Oil load cap 25 Nm (18.44 lbf ft) Bleeder cap 10 Nm (7.38 lbf ft)
  • Page 300 V85 TT Chassis Removing • Loosen and remove the screws (1). • Loosen and remove the screws (2). • Remove the gearbox (3). Replacement of the oil seal on the wheel hub with the bevel gear fitted on the vehicle CAUTION PROCEDURE VALID FOR VEHICLES EQUIPPED WITH BEVEL GEAR REV.2...
  • Page 301 V85 TT Chassis • Use a clamp to grab the screw and re- move the oil seal from the wheel hub seat • Insert a new oil seal in the specific seat, tap it inside with a tube with a slightly...
  • Page 302 V85 TT Chassis • Use threaded stud bolts as a guide and remove the flange. • Remove the ring gear axle thickness. CHAS - 302...
  • Page 303 V85 TT Chassis • Remove the inner spacer. • Remove the bearing's roller cage. • Using a suitable tool, disengage the ra- dial snap ring and remove it. • Heat the outer track seat of the roller bearing using an air heater.
  • Page 304 V85 TT Chassis • Insert the special tool under the washer and screw the cursor. Specific tooling 001467Y036 Bearing internal cup extractor • Insert a bush with a suitable diameter on the specific tool and tighten the nut keeping the extractor locked.
  • Page 305 V85 TT Chassis • Remove the sealing ring. • When reassembling use a new ring. CAUTION DURING REASSEMBLY BE CAREFUL, AS THE SEALING RING MUST BE INSERTED UNTIL IT STOPS, USING THE SPECIFIC PRESS-FIT PAD. • If the flange is provided with the cover (A) using a punch and operating in the inner part of...
  • Page 306 V85 TT Chassis • Unscrew the ring nut, using the special tool, to loose the riveting. • After unscrewing the ring nut to the end of the thread, re-tighten it until it stops in such a way as to create the space between the ring nut and the shoulder washer.
  • Page 307 V85 TT Chassis • Remove the ring nut. • Remove the crown gear. • Remove the gearbox flange from the splash guard hub. • Remove the O-ring. • When reassembling use a new O-ring. CAUTION PAY SPECIAL ATTENTION TO THE CORRECT REMOVAL PROCEDURE OF THE OIL SEAL TO AVOID THE DAMAGE OF THE STEEL SHEET UNDER THE OIL SEALER.
  • Page 308 V85 TT Chassis • Use a small self-tapping screw (M5- M6) and screw it slightly to grip on the oil seal. CAUTION DO NOT TIGHTEN THE SCREW AS IT COULD DAMAGE THE UNDERLYING THIN SHEET. • Using a clamp to remove the oil seal...
  • Page 309 V85 TT Chassis • Heat the outer area of the pinion bear- ings holder case • Using the special tool, loose and re- move the pinion bearings holder case. Specific tooling 020998Y Pinion case wrench • Using the specific tool, clamp the as- sembly in the vice and lift the nut again before removing it.
  • Page 310 V85 TT Chassis • Remove the sealing ring. • Remove the O-ring. Checking • Dopo il montaggio della scatola, è necessario verificare il gioco tra pignone e corona. Bloc- care in morsa il pignone e installare un comparatore mediante un supporto idoneo. Il tastatore del comparatore deve appoggiarsi all'estremità...
  • Page 311 V85 TT Chassis Assembling • Insert the new external O-ring in the pinion unit. • Insert the new internal O-ring in the pinion unit. • Insert a new seal ring until it stops • Insert the bearings closing spacer pay- ing attention that the chamfer is placed in contact with the O-ring.
  • Page 312 V85 TT Chassis • After having placed a new nut, using the specific tool, lock the assembly of the pinion bearing support case in the vice and tighten the nut to the prescri- bed torque. Specific tooling 021000Y Bevel gear set mounting •...
  • Page 313 V85 TT Chassis • On the opposite side of the cover, in- sert a new O-ring. • Before proceeding with the assembly of the hub, clean the surface on which the external O-rings of the cover will operate, using a sheet of abrasive mul- tipurpose sponge.
  • Page 314 V85 TT Chassis • Place a new ring nut and using the spe- cific tool tighten it to the prescribed torque. Specific tooling 020999Y Crown counter- lock ring wrench • Reattach the ring nut in two opposite points, in correspondence with the grooves on the hub.
  • Page 315 V85 TT Chassis • Insert the radial snap ring. • Using the specific tool, fit the internal oil seal of the bevel gear hub, bringing it to the end CAUTION ONLY FOR VEHICLES EQUIPPED WITH BEVEL GEAR REV.2 Specific tooling 020359S 42 x 47 mm punch •...
  • Page 316 V85 TT Chassis • Using the specific tool, put it in a press and insert the outer track of the roller bearing until it stops. Specific tooling 020360S Adaptor 52x54 mm • Insert the radial snap ring. • Insert the roller cage.
  • Page 317 V85 TT Chassis • Insert the inner spacer until it stops. • Reposition the crown axle thickness. NOTE THE THICKNESS HAS A UNIQUE POSITION IN THE BOX. PAY ATTENTION TO THE CORRECT POSITION BY CHECKING THE CORRESPONDENCE OF THE HOLES WITH THE FASTENING SCREWS.
  • Page 318 V85 TT Chassis • Insert the fixing screws of the flange and tighten it to the prescribed torque operating diagonally with the indicated sequence.. • Using a small brush, apply mineral grease to fill the area between the two oil seal lips and the dust guard of the cover, respecting the method shown in the photo on the side.
  • Page 319 V85 TT Chassis CAUTION ONLY FOR VEHICLES EQUIPPED WITH BEVEL GEAR REV.1 • After blowing the breather with com- pressed air, carefully remove any oil residues and check its correct func- tioning, put it in its seat again and tight- en it to the prescribed torque.
  • Page 320 V85 TT Chassis • Effettuare il riempimento olio seguendo quanto riportato nel capitolo "Manutenzione / Olio trasmissione / Sostituzione" See also Replacement Stand CHAS - 320...
  • Page 321 V85 TT Chassis TAND Pos. Description Type Quantity Torque Notes Side stand retainer pin 10 Nm (7.38 lbf ft) Nut fastening the side stand to the 30 Nm (22.13 lb ft) Loctite 243 stand mounting Screws fastening the stand mounting 50 Nm (36.88 lb ft)
  • Page 322 V85 TT Chassis • Holding the pin (5) in place, unscrew and remove the nut (6) • Remove the side stand (7). • Unscrew and remove the screws (8) • Unscrew and remove the screws (9) CHAS - 322...
  • Page 323 V85 TT Chassis • Remove the stand support (10) Exhaust - E4 ILENCER Pos. Description Type Quantity Torque Notes Lambda probe fastener 38 Nm (28.03 lb ft) Nut fixing exhaust manifolds to en- 25 Nm (18.44 lbf ft) gine Clamp fastening the compensator to 25 Nm (18.44 lbf ft)
  • Page 324 V85 TT Chassis - E5 ILENCER Pos. Description Type Quantity Torque Notes Lambda probe fastener 38 Nm (28.03 lb ft) Nut fixing exhaust manifolds to en- 25 Nm (18.44 lbf ft) gine Pipe clamp fixing to fasten the heat 3.5 Nm (2.58 lbf ft)
  • Page 325 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 NOTE PROCEDURE VALID ONLY FOR E4 VEHICLES • Remove the terminal •...
  • Page 326 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 327 V85 TT Chassis • Unscrew and remove the nuts (2) from both sides of the vehicle • Remove the exhaust manifold (3) NOTE PROCEDURE VALID ONLY FOR E5 VEHICLES • Remove the fixing screws (1) of the heat shield and remove it from the ve- hicle •...
  • Page 328 V85 TT Chassis • Remove the rear fixing screw (3) • Remove the fixing screws (4) from both sides of the vehicle • Remove the manifolds from the vehicle CHAS - 328...
  • Page 329 V85 TT Chassis Secondary air system Key: 1. Air filter box 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 330 V85 TT Chassis • Undo the screws fastening the reed valve cover. • Remove the reed valve cover CHAS - 330...
  • Page 331 V85 TT Chassis • Remove the reed valve. • Remove the flame trap. CHAS - 331...
  • Page 332 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 333 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
  • Page 334 V85 TT Braking system BRAKING SYSTEM Pos. Description Type Quantity Torque Notes Screw fastening the brake pipe to the 10 Nm (7.38 lbf ft) lower steering plate Rear screw fastening the brake pipe 10 Nm (7.38 lbf ft) to the frame...
  • Page 335 V85 TT Braking system EAR BRAKE PUMP Pos. Description Type Quantity Torque Notes Pin fastening the rear brake lever 6 Nm (4.43 lbf ft) spring coupling to the frame plate Screw fastening the rear brake lever 25 Nm (18.44 lbf ft)
  • Page 336 V85 TT Braking system EAR BRAKE CALLIPER Pos. Description Type Quantity Torque Notes Screws fastening the rear brake cal- 25 Nm (18.44 lbf ft) liper to the calliper support bracket Pin fastening the rear brake calliper 35 Nm (25.81 lb ft)
  • Page 337 V85 TT Braking system RONT BRAKE CALLIPER Pos. Description Type Quantity Torque Notes Screws fastening the front brake cal- 50 Nm (36.88 lb ft) liper to the calliper mounted bracket RONT BRAKE CALLIPER Pos. Description Type Quantity Torque Notes Screws fastening the front brake cal- 50 Nm (36.88 lb ft)
  • Page 338 V85 TT Braking system Key: 1. ABS Electronic Control Unit 2. Front ABS sensor 3. Rear ABS sensor 4. Battery 5. Starter relay 6. ECU 7. Instrument cluster 8. Line (diagnostics) 9. Starter motor 10.Voltage regulator 11.Secondary fuses 12.Main fuses...
  • Page 339 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 - 339...
  • Page 340 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 - 340...
  • Page 341 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 342 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 343 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 344 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 345 V85 TT Braking system 3. PERFORM THESE CHECKS: • A. PIN 1 Ground • B. +12V at PIN 18 4. ARE THERE ANY ERRORS? YES, go to point 5; NO, go to 6) 5. CHECK THE ERRORS TABLE 6. ABS WARNING LIGHT ACTIVATION IS IT ACTIVATED?(YES, go to point 7;...
  • Page 346 V85 TT Braking system • Undo and remove the screw (2) • 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...
  • Page 347 V85 TT Braking system • In order to ensure that the brake fluid remains inside the ABS control unit, first remove the protective plugs from the braking circuit couplings and connect the corresponding lines. • Once all the braking circuit lines have been connected, remove the protective plugs from the couplings of the brake master cylinders and connect the respective lines to the ABS control unit.
  • Page 348 V85 TT Braking system • If the initial position of the connector and the driving lever is not that shown in fig. 1, the connector will not be prop- erly coupled and the distance meas- ured will be greater (12 mm approx.
  • Page 349 V85 TT Braking system 0.1 - 3.10 mm (0.004 - 0.122 in) CLEANING THE PHONIC WHEELS • It is important to check that both phonic wheels are always clean. If not: delicately remove any dirt residues using a cloth or wire brush. Do not use solvents or abrasive substances and do not direct air or water jets directly on the phonic wheel.
  • Page 350 V85 TT Braking system • Unscrew and remove the joint screw (3) from the rear calliper • Unscrew and remove the screws (4) • Remove the rear calliper (5) Installing • Remove the rear brake calliper • Correctly position the new rear brake calliper (1) on the brake disc •...
  • Page 351 V85 TT Braking system • Hook the brake line into the cable grommet (4) • 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...
  • Page 352 V85 TT Braking system Removal The following procedure is described for a single calliper, but is valid for both front brake callipers. • Connect the bleeder bottles to the cal- liper bleeder screw and open • Press the lever down as far as it will go...
  • Page 353 V85 TT Braking system • Insert and tighten the screws (2) • Position the brake line on the brake calliper and insert and tighten the screw (3) • Remove the clamp from the front brake lever. • Remove the brake fluid reservoir cap and fill it with new brake fluid...
  • Page 354 V85 TT Braking system Disc thickness minimum value: 4.5 mm (0.18 Front brake disc Disc Inspection FRONT CAUTION THE FRONT BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE SPECIFICATIONS OF THE SYSTEM. • The following operations must be car- ried out with the brake discs fitted on the wheel;...
  • Page 355 V85 TT Braking system Removal The following procedure is described for a single calliper, but is valid for both front brake callipers. • Unscrew and remove the screws (1) • Remove the front brake calliper (2) from the brake disc •...
  • Page 356 V85 TT Braking system • Remove the spring (5) • 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 357 V85 TT Braking system • Insert the two pins (3) • Insert the two retaining springs (4) • Insert the front brake calliper (5) on the brake disc • Insert the two screws (6) and tighten them BRAK SYS - 357...
  • Page 358 V85 TT Braking system • Insert the front brake calliper (5) on the brake disc • Insert the two screws (6) and tighten them Rear brake pads Removal • Connect the bleeder bottles to the cal- liper bleeder screw and open •...
  • Page 359 V85 TT Braking system • Free the brake calliper line from the ca- ble grommet (2) • Unscrew and remove the two screws • Remove the rear brake calliper (4) from the brake disc • Unscrew and remove the two grub screws (5).
  • Page 360 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 361 V85 TT Braking system • Insert and tighten the screws (4) • Insert the brake calliper line into the cable grommet (5) • Tighten the two grub screws (2) Bleeding the braking system PREPARATION OF THE VEHICLE • It is important to ensure that there is always a sufficient quantity of brake fluid in the tank.
  • Page 362 V85 TT Braking system The presence of air is signalled by the "sponginess" of the brake and by poor braking. CONSIDERING THE DANGER FOR VEHICLE AND RIDER, IT IS STRICTLY NECESSARY, AFTER REFITTING THE BRAKE CALLIPERS AND RESTORING THE BREAKING SYSTEM TO ITS REG- ULAR USE CONDITIONS, SO THAT THE HYDRAULIC CIRCUIT IS AIR PURGED.
  • Page 363 V85 TT Braking system • Screw the bleeding valve and remove the pipe. • Top-up the reservoir until the correct brake fluid level is obtained. • Refit and block the front brake oil res- ervoir cap. • Refit the rubber protection cover.
  • Page 364 V85 TT Braking system • Remove the rear brake calliper fixing screws. • Remove the two cable tray fixing screws of the rear brake/rear ABS sen- sor wiring. • Release the rear ABS sensor wiring harness from the rubber bleed cap and from the brake pipe by disconnecting the two cable trays.
  • Page 365 V85 TT Braking system • Remove the rubber protection cover from the bleed valve. • Insert the transparent plastic pipe in the rear brake calliper bleed valve and insert the other end of this pipe into a container to collect the fluid.
  • Page 366 V85 TT Braking system • Refit the brake calliper and place the rubber protection cap again, paying attention during repositioning of the ABS wiring harness. REAR BLEEDING SYSTEM WITH DIAGNOSTIC TOOL If the brake pedal still feels "spongy" after completing all checks, it is necessary to bleed the brakes using this type of procedure.
  • Page 367 V85 TT Braking system Front brake pump Removal • Undo and remove the joint screw (1) from the front brake master cylinder af- ter placing a suitable container under- neath to collect the brake fluid • Unscrew and remove the screws (2) •...
  • Page 368 V85 TT Braking system • Remove the sensor (5) from the front brake master cylinder • Remove the front brake master cylin- der (6) Rear brake pump Rimozione • Unscrew and remove the two screws • Remove the protection cover (2)
  • Page 369 V85 TT Braking system • 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. • Remove the rear brake master cylinder REAR BRAKE FLUID RESERVOIR REMOVAL •...
  • Page 370 V85 TT Braking system • Remove the locking clip (2) • Remove the rear brake master cylinder plunger (3) BRAK SYS - 370...
  • Page 371 INDEX OF TOPICS BODYW ODYWORK...
  • Page 372 V85 TT Bodywork NDER SEAT COMPARTMENT Pos. Description Type Quantity Torque Notes Screw fastening the front brake pipe 6 Nm (4.43 lbf ft) feedthrough to the battery box Screws fastening the battery box to 6 Nm (4.43 lbf ft) the frame Screws fastening battery bracket/ 6 Nm (4.43 lbf ft)
  • Page 373 V85 TT Bodywork RAME Pos. Description Type Quantity Torque Notes Screws fastening muffler support 10 Nm (7.38 lbf ft) bracket to the frame Screws fastening frame to the engine 50 Nm (36.88 lb ft) Screws fastening voltage regulator 10 Nm (7.38 lbf ft)
  • Page 374 V85 TT Bodywork OCKS Pos. Description Type Quantity Torque Notes Screw fastening the starter switch to 25 Nm (18.44 lbf ft) the frame Screw fastening the starter switch to Shear head screw the frame until it breaks Screws fastening the fuel tank cap to 6 Nm (4.43 lbf ft)
  • Page 375 V85 TT Bodywork UEL TANK Pos. Description Type Quantity Torque Notes Screws fastening the fuel tank to 10 Nm (7.38 lbf ft) frame Ring nut fastening the fuel pump to 20 Nm (14.75 lbf ft) the fuel tank BODYW - 375...
  • Page 376 V85 TT Bodywork UARDS Pos. Description Type Quantity Torque Notes Screws fastening the fork guards to 6 Nm (4.43 lbf ft) the fork stanchions Screws fastening the headstock cov- Self-tapping 3 Nm (2.21 lbf ft) er to the connectors box...
  • Page 377 V85 TT Bodywork EAR BRAKE PUMP Pos. Description Type Quantity Torque Notes Pin fastening the rear brake lever 6 Nm (4.43 lbf ft) spring coupling to the frame plate Screw fastening the rear brake lever 25 Nm (18.44 lbf ft)
  • Page 378 V85 TT Bodywork OOTRESTS Pos. Description Type Quantity Torque Notes Screws for fastening the passenger's 25 Nm (18.4 lb ft) footrests supports to the frame sup- port Screws fastening the footrest rubber 10 Nm (7.38 lbf ft) to the footrest Screws fastening the passenger heel 10 Nm (7.38 lbf ft)
  • Page 379 V85 TT Bodywork EAR MUDGUARD Pos. Description Type Quantity Torque Notes Screws fastening the licence plate Self-tapping 3 Nm (2.21 lbf ft) holder fastener to the licence plate 3.9x14 holder Screws fastening the licence plate 8 Nm (5.90 lb ft)
  • Page 380 V85 TT Bodywork ANDLEBAR ONTROLS Pos. Description Type Quantity Torque Notes Screws fastening the lower U-bolts to 50 Nm (36.88 lb ft) the upper steering yoke Screws fastening the lower U-bolt 25 Nm (18.44 lbf ft) clamp to the handlebar Screws fastening the handguards 10 Nm (7.38 lbf ft)
  • Page 381 V85 TT Bodywork EARBOX LEVER Pos. Description Type Quantity Torque Notes Screw fastening left frame plate to 25 Nm (18.44 lbf ft) the gearbox Nut fastening the gear control link- Manual with tem- age to the gear lever plate Nut fastening the gear control link-...
  • Page 382 V85 TT Bodywork AILLIGHT Pos. Description Type Quantity Torque Notes Taillight to number plate holder fixing Self-tapping 3 Nm (2.21 lbf ft) screws 5x14 Rear direction indicator to number 3 Nm (2.21 lbf ft) With self-locking nut plate holder fixing screws Licence plate light to number plate 3 Nm (2.21 lbf ft)
  • Page 383 V85 TT Bodywork OP FAIRING INDSHIELD Pos. Description Type Quantity Torque Notes Front screw fastening the windshield 10 Nm (7.38 lbf ft) to the front frame Rear screw fastening the windshield 10 Nm (7.38 lbf ft) to the front frame Screw fastening the windshield sup- 10 Nm (7.38 lbf ft)
  • Page 384 V85 TT Bodywork HROTTLE BODY Pos. Description Type Quantity Torque Notes Screw fastening the injector caps to 6 Nm (4.43 lbf ft) the in take fittings UEL TANK COVER Pos. Description Type Quantity Torque Notes Screws fastening the ignition block 4 Nm (2.95 lb ft)
  • Page 385 V85 TT Bodywork Pos. Description Type Quantity Torque Notes Screws fastening the tank cap cover 4 Nm (2.95 lb ft) to the fuel tank Stud bolt fastening the side tank cov- 4 Nm (2.95 lb ft) er support to the fuel tank Front screws fastening the tank cov- 4 Nm (2.95 lb ft)
  • Page 386 V85 TT Bodywork ENTRAL BODYWORK Pos. Description Type Quantity Torque Notes Screws fastening the side panels to 6 Nm (4.43 lbf ft) the frame BODYW - 386...
  • Page 387 V85 TT Bodywork ILTER BOX Pos. Description Type Quantity Torque Notes Screws fastening the filter casing to 10 Nm (7.38 lbf ft) the frame Screws fastening the intake duct to TCB 4.2x16 3 Nm (2.21 lbf ft) the filter casing cover Screws fastening the throttle body to 10 Nm (7.38 lbf ft)
  • Page 388 V85 TT Bodywork • Recover the two washers before re- moving the lumbar support. • Remove the lumbar support • To remove and eventually replace the rubber supports, simply turn them slightly and pull them outwards. Side fairings REMOVAL The following procedure is described for a single side bumper, but is valid for both side bumpers.
  • Page 389 V85 TT Bodywork • Remove the side bumpers (2) Rear rack LUGGAGE RACK COVER REMOVAL • Holding the nuts still located on the lower part of the area indicated in the figure, loosen and remove the screws • Remove the luggage rack cover (2) LUGGAGE RACK REMOVAL •...
  • Page 390 V85 TT Bodywork • Unscrew and remove the screws (2) • Remove the luggage rack (3) Hand guards HAND-GUARDS The following procedure is described for a single hand guard, but is valid for both hand guards. • Remove the rear view mirrors •...
  • Page 391 V85 TT Bodywork • Retrieve the counterweight (3) HEATED HAND GRIPS To remove the heated handles, first remove the fuel tank. Then proceed according to the following instructions: LEFT SIDE HEATED HANDLE • Operating from both sides of the mo- torcycle, remove the protection covers (1) of the steering headstock.
  • Page 392 V85 TT Bodywork • Remove the screw (4) that fastens the hand guard to the counterweight. • Remove the two screws (5) that fasten the heated handle to the handlebar. • Unscrew and remove the counter- weight (6) and remove the handle (7) from the handlebar.
  • Page 393 V85 TT Bodywork • Remove the clamp (10) that fastens the throttle control wiring harness. • Disconnect the throttle control connec- tor (11). • Remove the two rubber fairleads (12) and release the wiring harnesses. • Remove the screw (13) that fastens the hand guard to the counterweight.
  • Page 394 V85 TT Bodywork • Remove the screw (14) that fastens the throttle control/heated handle to the handlebar. CAUTION WHILE REFITTING, PAY ATTENTION TO CORRECTLY PO- SITION THE THROTTLE CONTROL, WHICH MUST ALLOW THE STARTER BUTTON TO BE FULLY PRESSED, AS IN- DICATED.
  • Page 395 V85 TT Bodywork • Remove the rear view mirror (4) • Undo and remove the locknut (2) Instrument panel REMOVAL • Remove the headlight • Unscrew and remove the screws (1) • Disconnect the connector (2) BODYW - 395...
  • Page 396 V85 TT Bodywork • Remove the instrument panel (3) Headlight assy. REMOVAL • Remove the top fairing • Unscrew and remove the screws (1) • Unscrew and remove the screws (2) • Remove the cover (3). BODYW - 396...
  • Page 397 V85 TT Bodywork • Remove the connector (4) from the support as indicated in the figure • Disconnect the connector (4) • Undo and remove the screw (5) • Undo and remove the screw (6) BODYW - 397...
  • Page 398 V85 TT Bodywork • Undo and remove the screw (7) • Remove the wiring as indicated in the figure • Remove the front light assembly (8) • Retrieve the bushings (9) BODYW - 398...
  • Page 399 V85 TT Bodywork Horn REMOVAL • Disconnect the connectors (1) • Undo and remove the screw (2) • Remove the horn (3) Additional lights • Remove the windshield and then, op- erating from both sides, remove the screws (1) used to fasten the wind- shield support (2).
  • Page 400 V85 TT Bodywork • Remove the two rear fixing screws (5) of the instrument panel closing cover. • Remove the instrument panel closing cover (4). THE FOLLOWING OPERATIONS REFER TO ONE FOG LIGHT BUT ARE VALID FOR BOTH FOG LIGHTS •...
  • Page 401 V85 TT Bodywork • Keep the screws (8) in place and un- screw and remove the fixing nuts (9) of the fog light. • Remove the fog light. Turn indicators REMOVING FRONT TURN INDICATORS • Remove the top fairing •...
  • Page 402 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 403 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 - 403...
  • Page 404 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 405 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 406 V85 TT Bodywork • Remove the licence plate light (2) Footrest CAUTION IF THE TYPE "1" SEEGER-RINGS ARE PRESENT, RE- PLACE THEM WITH TYPE "2" ONES REMOVING THE PASSENGER FOOTRESTS The following procedure is described for a single footrest, but is valid for both passenger footrests.
  • Page 407 V85 TT Bodywork • Remove the passenger footrest (3) • 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.
  • Page 408 V85 TT Bodywork RIDER FOOTREST REMOVAL The following procedure is described for a single footrest, but is valid for both rider footrests. • Remove the snap ring(1) • Remove the pin (2) • Remove the rider footrest (3) REMOVING THE GEAR SHIFT LEVER •...
  • Page 409 V85 TT Bodywork • Remove the gear shift lever from the spherical joint (2) • Undo and remove the screw (3) • Remove the gear lever (4) • Retrieve the bushing (5) and the two O- rings (6) BODYW - 409...
  • Page 410 V85 TT Bodywork REMOVING THE REAR BRAKE LEVER • Holding the nut (2) so that it cannot ro- tate, remove the screw (1) • Remove the rear brake lever (3) • Retrieve the nut (2) and the washer (4) •...
  • Page 411 V85 TT Bodywork RIGHT RIDER FOOTREST BRACKET REMOV- • Remove the rear brake master cylin- der, brake master cylinder plunger and front brake lever • Undo and remove the screw (1) • Undo and remove the screw (2) • Undo and remove the screw (3) •...
  • Page 412 V85 TT Bodywork • Hold the nut (7) from the opposite side so that it cannot rotate and remove the screw (8) • Rotate the plate 180°, undo and re- move the screws (9) and remove the bracket (10) •...
  • Page 413 V85 TT Bodywork LEFT RIDER FOOTREST BRACKET REMOVAL • Remove the safety clip (1) • Remove the gear shift lever from the spherical joint (2) • Undo and remove the screw (3) • Undo and remove the screw (4) BODYW - 413...
  • Page 414 V85 TT Bodywork • Undo and remove the screw (5) and retrieve the bushing (6) • 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) •...
  • Page 415 V85 TT Bodywork • Remove the left rider footrest bracket plate (12) 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) •...
  • Page 416 V85 TT Bodywork • Remove the fuses (2) from the support indicated in the figure • Remove the glove compartment (3) Side fairings REMOVAL • Remove the fuel tank • Unscrew and remove the screws (1) • Unscrew and remove the screws (2)
  • Page 417 V85 TT Bodywork • Unscrew and remove the screws (3) • Unscrew and remove the screws (4) • Remove the left side engine fairing (5) • Remove the right side engine fairing BODYW - 417...
  • Page 418 V85 TT Bodywork Fairing mounting panels REAR BRAKE HOSE GUIDE REMOVAL • Undo and remove the screw (1) • Undo and remove the screw (2) • Remove the cable grommet (3) • Remove the rear brake hose guide (4) BODYW - 418...
  • Page 419 V85 TT Bodywork UNDER-SADDLE COMPARTMENT/BATTERY BOX REMOVAL • Remove the side fairing panels • Remove the licence plate holder brack- • Remove the fuse box (1) • Unscrew and remove the screws (2) • Unscrew and remove the screws (3) •...
  • Page 420 V85 TT Bodywork • Unscrew and remove the screws (5) • 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)
  • Page 421 V85 TT Bodywork • Support the licence plate bracket • Unscrew and remove the screws (3) • Remove the licence plate bracket cov- er (4) • Remove the wiring from the cable glands (5) • Remove the wiring from the cable glands (6) •...
  • Page 422 V85 TT Bodywork • Disconnect the left turn indicator con- nector (8) • 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 •...
  • Page 423 V85 TT Bodywork Air box REMOVAL • Remove the saddle • Remove the glove compartment • Remove the side fairing panels • Unhook and remove the four springs (1) located around the airbox filter, two in the upper area, one on the left side and one on the right side •...
  • Page 424 V85 TT Bodywork • Loosen the clamp (5) • Disconnect the pipe (6) • Remove the plastic rivet (7) • Unscrew and remove the screws (8) • Disconnect the connector (9) • Momentarily remove the support bracket (10) from the frame •...
  • Page 425 V85 TT Bodywork • Disconnect the connector (13) • 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 four screws (1) fastening the sump guard to the support bracket •...
  • Page 426 V85 TT Bodywork CAUTION DURING THE REASSEMBLY, CHECK THE CORRECT PO- SITIONING OF THE BUSHINGS ON THE RUBBERS, WHICH SHALL BE AS SHOWN IN THE IMAGE (THE VIEW SHOWS THE INTERNAL SIDE OF THE SUMP GUARD). • Remove the four screws (3) fastening the support bracket to the sump guard (4).
  • Page 427 V85 TT Bodywork • Undo and remove the screw (2) • Undo and remove the screw (3) • Remove the ignition switch assembly cover (4) • Unscrew and remove the screws (5) BODYW - 427...
  • Page 428 V85 TT Bodywork • Undo and remove the screw (6) • Disconnect the connector (7) • Disconnect the fuel pump hose (8) • Loosen the clamp (9) and disconnect the hose (10) BODYW - 428...
  • Page 429 V85 TT Bodywork • Lifting the front part of the fuel tank, loosen the clamp (11) and disconnect the hose (12) • Remove the fuel tank (13) TANK FILLER CAP REMOVAL • Open the tank filler cap • Unscrew and remove the screws (1) •...
  • Page 430 V85 TT Bodywork CENTRAL TANK FAIRING REMOVAL • Undo and remove the screw (1) • Unscrew and remove the screws (2) • Undo and remove the screw (3) • Unscrew and remove the screws (4) BODYW - 430...
  • Page 431 V85 TT Bodywork • Remove the central tank fairing (5) 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 BODYW - 431...
  • Page 432 V85 TT Bodywork • Retrieve the bushings (4) • Unscrew and remove the screws (5) • Remove the mudguard cover (6) • Undo and remove the screws (7) BODYW - 432...
  • Page 433 V85 TT Bodywork • Remove the grille (8) Side panniers The side cases are attached to the chassis using the specific supports. To remove them, proceed as follows: REMOVING THE LOWER CENTERING BRACK- THE FOLLOWING OPERATIONS REFER TO A SINGLE BRACKET BUT APPLY TO BOTH SIDES •...
  • Page 434 V85 TT Bodywork • Remove the upper support (2) CASE DISASSEMBLY THE FOLLOWING OPERATIONS REFER TO A SINGLE BRACKET BUT APPLY TO BOTH SIDES • After removing the case from the mo- torcycle, open it and remove the fixing screws (1), complete with washers (2) and bushings (3) to remove the two side stands of the cover.
  • Page 435 V85 TT Bodywork • Remove the ten fixing screws (6) to re- move the four covers (7) on the case cover. THE OPERATION DESCRIBED IS RELATED TO A SINGLE CLOSURE LEVER BUT IS VALID FOR BOTH • To remove the closing levers of the ca-...
  • Page 436 V85 TT Bodywork • Remove the fixing screw (12) with the spring washer (13) and the lock plate (14). NOTE DURING THE REFITTING PAY ATTENTION TO THE DIREC- TION OF ASSEMBLY OF THE SPRING WASHER (13) AND THE LOCK PLATE (14).
  • Page 437 V85 TT Bodywork • Working on the case, remove the pro- tective cover (20) of the latch • Remove the two fixing screws (21) and remove the handle complete (22). • Remove the fixing screw (23) with the spring washer (24) and the latch (25).
  • Page 438 V85 TT Bodywork • Remove the fastening nut (28) of the latch. • Remove the knurled washer (29) and remove the latch (30) from the case. • To disassemble the handle, remove the three screws (31) and recover the cover (32).
  • Page 439 V85 TT Bodywork • Separate the handle (34) from the sup- port (35) • Remove the return spring (36) from the handle pin, paying attention to the di- rection of assembly during the reas- sembly phase. Instrument cluster support REMOVAL •...
  • Page 440 V85 TT Bodywork • Remove the connector (3) from the guide indicated in the figure • Disconnect the connector (3) • Remove the plastic rivet (4) • Remove the plastic rivets from both sides of the vehicle (5) • Unscrew and remove the screws (6)
  • Page 441 V85 TT Bodywork • Remove the support (7) • Remove the USB socket (8) • Disconnect the front turn indicator con- nectors (9) • Unscrew the two screws (10) from both sides of the vehicle BODYW - 441...
  • Page 442 V85 TT Bodywork • Remove the front turn indicators from both sides of the vehicle (11) • Block the nuts (12) and unscrew and remove the screws (13) • Remove the connector (14) from the guide indicated in the figure •...
  • Page 443 V85 TT Bodywork • Remove the support (16) • Remove the clamp (17) • Remove the air temperature sensor (18) Battery REMOVAL • Remove the glove compartment • Undo and remove the screw (1) • Remove the negative cable from the battery (2) •...
  • Page 444 V85 TT Bodywork • Remove the battery (6) Tail guard REAR FAIRINGS REMOVAL • Remove the luggage rack • Unscrew and remove the screws (1) • Unscrew and remove the screws (2) • Remove the rear fairing (3) • Undo and remove the screw (4)
  • Page 445 V85 TT Bodywork • Remove the right rear fairing (5) • Undo and remove the screw (6) • Remove the left rear fairing (7) Copertura terminale REMOVAL • Unscrew and remove the screws (1) BODYW - 445...
  • Page 446 V85 TT Bodywork • Remove the left cover (2) • Unscrew and remove the screws (3) • Remove the terminal cover (4) • Retrieve the washers (5) BODYW - 446...
  • Page 447 ABS: 207, 338 Air filter: 76 Battery: 157, 443 Brake: 195, 349, 351, 353, 354, 358, 367, 368 Brake calliper: 349, 351 Brake disc: 353, 354 Brake pads: 354, 358 Brake pump: 367, 368 Bulbs: CAN line: 210 Cardan shaft: 297 Clutch: 83, 191 Coil: 182 Connectors: 197...
  • Page 448 Intake pressure sensor: 164 Keys: 146 License plate holder: 420 Luggage rack: Maintenance: 21, 67, 150, 348 Mirrors: 394 Mudguard: 431 Oil filter: 75 Oil pressure sensor: 189 Rear wheel: 287 Recommended products: 70 Saddle: SAS valve actuator: 194 Scheduled maintenance: 67 Secondary air system: 329 Shock absorber: Shock absorbers: 273...

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