Page 1 SERVICE STATION MANUAL 2Q000383 Engine V85 E4...
Page 2 The reliability of the vehicle also depends on its mechanical conditions. Checking the vehicle before riding it, its regular maintenance and the use of original Moto Guzzi spare parts only are essential factors! For information on the nearest Official Dealer and/or Service Centre consult our website: www.motoguzzi.com...
Page 3 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 vehicle.
Page 5: Index Of Topics
INDEX OF TOPICS CHAR HARACTERISTICS S-TOOLS PECIAL TOOLS NGINE...
Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...
Page 7: Tightening Torques
Engine V85 E4 Characteristics Tightening Torques If the following tables do not expressly indicate the tightening torque values, refer to the table with the generic torque values indicated below. ENERAL TIGHTENING TORQUES Metric tightening torque: TE - TEFL - SHC - TBEI 3 Nm (2.21...
Page 8 Engine V85 E4 Characteristics Pos. Description Type Quantity Torque Note Crankcase half nuts 22-25 Nm (16.23-18.44 lb ft) Crankcase half stud bolts 22-25 Nm (16.23-18.44 Pre-applied Loct.; lb ft) alternatively Loct. 2510 Crankcase half stud bolts 22-25 Nm (16.23-18.44 Loct. 648...
Page 9 Engine V85 E4 Characteristics EADS COVERS Pos. Description Type Quantity Torque Note Spark plugs cover hex socket screws M5x12 6-8 Nm (4.42-5.90 lb ft) Head covers screws 9-11 Nm (6.64-8.11 lb Rounded head torx screws for spark 2.6-3.1 Nm (1.92-2.29...
Page 10 Engine V85 E4 Characteristics ALVES Pos. Description Type Quantity Torque Note Stud bolts for exhaust manifolds 20-24 Nm (14.75-17.70 lb ft) IMING SYSTEM Pos. Description Type Quantity Torque Note Tone wheel flanged hex head screw M7x18 16-17 Nm (11.80-12.54 Pre-applied Loct. -...
Page 11 Engine V85 E4 Characteristics Pos. Description Type Quantity Torque Note Stud bolt fixing nut (pre-tightening) 9-11.5 Nm (6.64-8.48 lb Lubricate the threads and the support surface with MOLYCOTE GRAPID PLUS SPRAY grease Stud bolt fixing nut (final tightening) 88°-92° - 14-18 Nm Lubricate the (10.32-13.28 lbf ft)
Page 12 Engine V85 E4 Characteristics RANKSHAFT Pos. Description Type Quantity Torque Note Crankshaft plug 15-18 Nm (11.06-13.28 Loct. 648 lb ft) Connecting rods screws (pre-tight- 10 Nm (7.37 lb ft) Lubricate the thread ening 1st coupling) and underhead with Pankl PLB 19 Connecting rods screws (pre-tight- 20 Nm (14.75 lbf ft)
Page 13 Engine V85 E4 Characteristics OMPLETE GEAR ELECTOR ESMODROMIC Pos. Description Type Quantity Torque Note Clutch housing/gearbox fastening M6x55 9-11 Nm (6.64-8.11 lb SHC screws Engine / gearbox fastening SHC M8x40 24-28 Nm (17.70-20.65 screws lb ft) Oil load cap 23-27 Nm (16.96-19.91...
Page 14 Engine V85 E4 Characteristics OMPLETE GEAR ELECTOR ESMODROMIC Pos. Description Type Quantity Torque Note Clutch housing/gearbox fastening M6x55 9-11 Nm (6.64-8.11 lb SHC screws Engine / gearbox fastening SHC M8x40 24-28 Nm (17.70-20.65 screws lb ft) Oil load cap 23-27 Nm (16.96-19.91...
Page 15 Engine V85 E4 Characteristics EARBOX COMPONENTS Pos. Description Type Quantity Torque Note Bearing stoppers countersunk hex M6x12 9-11 Nm (6.64-8.11 lb Pre-applied Loct.; head screws alternatively 3M SCOTCH-GRIP 2353 or Loct. DRI LOC 2045 BLU CHAR - 15...
Page 16 Engine V85 E4 Characteristics UBRICATION Pos. Description Type Quantity Torque Note Cover and oil filter cartridge fixing M8x105 18-22 Nm (13.28-16.23 hex head screw lb ft) Oil filter joint 20-24 Nm (14.75-17.70 lb ft) Oil sump drainage plug 20-24 Nm (14.75-17.70...
Page 17 Engine V85 E4 Characteristics LUBRICATION Pos. Description Type Quantity Torque Note Cover and oil filter cartridge fixing M8x105 18-22 Nm (13.28-16.23 hex head screw lb ft) Oil filter joint 20-24 Nm (14.75-17.70 lb ft) Oil sump drainage plug 20-24 Nm (14.75-17.70...
Page 18 Engine V85 E4 Characteristics LUTCH Pos. Description Type Quantity Torque Note Clutch-crankshaft screws 38-42 Nm (28.03-30.98 Loct. 243 lb ft) Starter sprocket fixing torx rounded M6x20 9-11 Nm (6.64-8.11 lb Pre-applied Loct.; head screws alternatively Loct. DRI-LOC 2040 or 3M SCOTCH GRIP...
Page 19 Engine V85 E4 Characteristics AGNETO FLYWHEEL TART Pos. Description Type Quantity Torque Note Stator SHC screws M6x20 9-11 Nm (6.64-8.11 lb Loct. 243 Flywheel flanged hex head screw M14x30 114-125 Nm (84.08-92.19 lb ft) Flanged hex head screws for cable M5x12 5-6 Nm (3.69-4.42 lb ft)
Page 20 Engine V85 E4 Characteristics ECONDARY AIR SYSTEM Pos. Description Type Quantity Torque Note Secondary air covers SHC screws 3-4 Nm (2.21-2.95 lb ft) CHAR - 20...
Page 21: Index Of Topics
INDEX OF TOPICS S-TOOLS PECIAL TOOLS...
Page 22 Engine V85 E4 Special tools SPECIAL TOOLS Stores code Description 020997Y Engine support plate 020382Y Tool to extract valve cotters GU19927100 Tool for mounting seal ring on flange on the flywheel side 020995Y Rocker arm centring pin 020128Y Piston fitting ring...
Page 23 Engine V85 E4 Special tools Stores code Description 020713Y Flywheel extractor 020976Y Clutch control dust guard mounting punch 021020Y Clutch housing oil seal mounting punch 021001Y Clutch retainer tool 021002Y Clutch centring S-TOOLS - 23...
Page 24 INDEX OF TOPICS NGINE...
Page 25 Engine V85 E4 Engine Gearbox Diagram key: 1. Thrust washer 2. 2nd speed gear on main shaft 3. Circlip 4. Thrust washer 5. 6th speed gear on main shaft 6. Floating bushing 7. Main shaft thrust washer 8. 3rd and 4th speed sliding gear on main shaft 9.
Page 26: Removing The Gearbox
Engine V85 E4 Engine 17.Floating bushing 18.Thrust washer 19.Circlip for the shaft 20.6th speed gear on transmission shaft 21.Circlip for the shaft 22.Thrust washer 23.3rd speed gear on transmission shaft 24.Floating bushing 25.4th speed gear on transmission shaft 26.Floating bushing 27.Thrust washer...
Page 27 Engine V85 E4 Engine • Remove the fixing screw (2) of the gearbox, placed from the engine crankcase side • Remove the complete gearbox screw Gearbox shafts Disassembling the gearbox • Remove the 12 fixing screws of the gearbox, engine side.
Page 28 Engine V85 E4 Engine • Remove the external body (1), the thrust bearing (2) and two related slid- ing washers (3) and the external body (4). • Remove the pusher plate • Remove the gearbox cover with a few mallet strokes...
Page 29 Engine V85 E4 Engine • The bearings from the gearbox crank- cases can be removed using generic extractors. • Heat the primary shaft bearing area on the base of the gearbox crankcase and the secondary shaft area on the gear- box crankcase cover very well with a hair dryer.
Page 30 Engine V85 E4 Engine • Remove the gear selector shaft, the desmodromic shaft and the forks with shaft • Remove the complete gear unit To dismantle the main shaft, proceed as follows: • Remove the shim washer (1) • Remove the gear of the 2nd gear (2) •...
Page 31 Engine V85 E4 Engine • Remove the spacer (4) • Remove the gear of the 6th gear (5) • Remove the bushing (6) • Remove the spacer (7) ENG - 31...
Page 32 Engine V85 E4 Engine • Remove the gear of the 3-4th gear (8) • Using the appropriate jaws, lock the primary shaft in a vice and remove the circlip (9) • Remove the spacer (10) • Remove the gear of the 5th gear (11)
Page 33 Engine V85 E4 Engine • Remove the bushing (12) • Remove the washer (13) from the main shaft (14) Removing the secondary shaft CAUTION FIT NEW CIRCLIPS WHEN REASSEMBLING Disassemble the secondary shaft as follows: • Remove the shim washer (1) •...
Page 34 Engine V85 E4 Engine • Remove the bushing (3) • Remove the shim washer (4) • Remove the seeger ring (5) • Remove the gear of the 5th gear (6) ENG - 34...
Page 35 Engine V85 E4 Engine • Remove the seeger ring (7) • Remove the shim washer (8) • Remove the gear of the 4th gear (9) • Remove the bushing (10) ENG - 35...
Page 36 Engine V85 E4 Engine • Remove the gear of the 3rd gear (11) • Remove the bushing (12) • Remove the shim washer (13) • Remove the seeger ring (14) ENG - 36...
Page 37 Engine V85 E4 Engine • Remove the gear of the 6th gear (15) • Remove the seeger ring (16) • Remove the shim washer (17) • Remove the gear of the 2nd gear (18) ENG - 37...
Page 38 Engine V85 E4 Engine • Remove the bushing (19) Desmodromic demounting • Remove the fork carrier shaft (1). • Remove the desmodromic shaft (2). • The forks are marked with a serial number that indicated the correct posi- tioning. •...
Page 39: Disassembling The Clutch Shaft
Engine V85 E4 Engine • Remove the lower fork No.3 (4) • Remove the primary and secondary shaft, as well as the intermediate fok No. 2 Disassembling the clutch shaft • To remove the clutch shaft it is neces- sary to remove first all gearbox com-...
Page 40 Engine V85 E4 Engine • Remove the oil seal CAUTION IN CASE OF OIL SEAL REPLACEMENT, USE THE SUITA- BLE PUNCH UNTIL IT REACHES THE CRANKCASE Specific tooling 021020Y Clutch housing oil seal mounting punch CLUTCH SHAFT DISASSEMBLY • Using a hydraulic press and a generic...
Page 41 Engine V85 E4 Engine WEAR LIMITS Specification Desc./Quantity Maximum wear limit for the selection gear grooves 22.78 mm (0.896 in) with rollers diam. 3.5 mm (0.14 in) Minimum wear limit of the cardan shaft side secondary shaft 23.294 mm (0.9171 in) with rollers diam. 3.0 mm (0.12 in)
Page 42: Assembling The Gearbox
Engine V85 E4 Engine Assembling the gearbox • In case of secondary oil seal replace- ment of the cardan on the gearbox cov- er, use the special punch until it stops. Specific tooling 020978Y Cardan secondary oil seal mounting punch •...
Page 43 Engine V85 E4 Engine • After inserting all the internal compo- nents, apply a layer of threebond 1207B on the junction surface of the two crankcasings. • Position the gearbox cover and man- ually tighten the gearbox fixing screw on the cardan side.
Page 44: Gear Selector
Engine V85 E4 Engine • Insert the intermediate body (3), the thrust bearing (4) and two related slid- ing washers (5) and the external body (6). Gear selector Removing the gear selector • Remove the desmodromic shaft first and then the complete gear selector shaft (1).
Page 45 Engine V85 E4 Engine • Remove the seeger ring (4) • Remove the seeger ring (5) • Remove the washer (6) • Remove the bushing (7) ENG - 45...
Page 46 Engine V85 E4 Engine • Remove the selector spring (8) • Remove the ring (9) • Remove the bushing (10) WARNING DURING REFITTING, PAY ATTENTION TO THE CORRECT POSITIONING OF THE BUSHING, AS THE SIDES ARE NOT SYMMETRICAL • Remove the index lever (11)
Page 47 Engine V85 E4 Engine • Remove the selector return spring (13) Generatore Rimozione sensore giri NOTE PROCEDURE VALID ONLY FOR E4 VEHICLES • Undo and remove the fixing screw of the sensor • Remove the timing system cover sen- ENG - 47...
Page 48: Generator Removal
Engine V85 E4 Engine Generator removal ALTERNATOR COVER REMOVAL • Remove the alternator cover fixing screws • Remove the alternator cover. • Remove the gasket. ROTOR REMOVAL • From the clutch side, partially unscrew the two fixing screws of the clutch...
Page 49 Engine V85 E4 Engine • Using one of the fixing screws of the gearbox assembly, secure the specific tool. • Place the tool (1) on the rotor, tighten the threaded pin (2) of the tool and pro- ceed with the rotor removal...
Page 50 Engine V85 E4 Engine • Extract the oil seal NOTE PROCEDURE VALID ONLY FOR E4 VEHICLES STATOR REMOVAL • Remove the stator wiring harness lock plate • Removing the three stator fixing screws makes it possible to disconnect NOTE PROCEDURE VALID ONLY FOR E5 VEHICLES STATOR REMOVAL •...
Page 51: Generator Installation
Engine V85 E4 Engine • Remove the three fixing screws fas- tening the stator to the timing system cover • At this point, the stator can be removed from the cover, together with the wiring harness and the pick-up Generator Installation...
Page 52 Engine V85 E4 Engine • During refitting of the flywheel cover it is necessary to apply a great amount of threebond on the cable grommet of the stator before placing it in its seat • Check that plentiful threebond leaks...
Page 53: Removing The Starter Motor
Engine V85 E4 Engine • Use P.A.D.S. to "RESET THE TONE WHEEL VALUES". This item can be selected from the following path: "Ad- justments" - "ECU EEPROM reset" • Bring the engine to a temperature of 80° • With the gearbox in neutral and the ve-...
Page 54: Disassembling The Clutch
Engine V85 E4 Engine Disassembling the clutch • Remove the clutch cover. • Partially unscrew the two fixing screws of the clutch plate, as indicated, to al- low the correct positioning of the spe- cific clutch lock tool. Specific tooling 021001Y Clutch retainer tool •...
Page 55 Engine V85 E4 Engine • Remove the clutch disc. • Remove the retainer ring • Remove the thrust plate • Remove the 6 fixing screws of the lock- ing plate ENG - 55...
Page 56: Checking The Clutch Plates
Engine V85 E4 Engine • Remove the reinforcement flange of the clutch thrust plate • Remove the clutch lock complete • Remove the spacer plate. Checking the clutch plates Clutch disc Make sure that the clutch plate is not scratched or badly worn. Check the flexible springs and the...
Page 57: Assembling The Clutch
Engine V85 E4 Engine Starting sprocket Check that the supporting surface with the driven plate is perfectly smooth and even. Also check that the toothing where the starter mo- tor pinion works is not chipped or scratched; oth- erwise, replace it.
Page 58 Engine V85 E4 Engine • Insert the 6 fastening screws complete with washers and tighten to the pre- scribed torque • Insert the thrust plate cap • Lock the thrust plate using the special lock ring • Place the clutch plate...
Page 59 Engine V85 E4 Engine • Place the starter sprocket and screw the fixing screws by hand • Using the special tool for the centring of the clutch plate Specific tooling 021002Y Clutch centring • Insert the six fastening screws at the recommended torque.
Page 60 Engine V85 E4 Engine RANKCASE HOLE DIAMETER Specification Desc./Quantity Class 1 Bushing seat diameter: 43.657-43.663 mm (1.7188-1.7190 in) Class 2 Bushing seat diameter: 43.664-43.670 mm (1.7191-1.7193 in) Class 3 Bushing seat diameter: 47.130-47.136 mm (1.8555-1.8557 in) Class 4 Bushing seat diameter: 47.137-47.142 mm (1.8558-1.8560 in) Four different crankcase classes are available: •...
Page 61 Engine V85 E4 Engine Or alternatively, laterally on the counterweights of the crankshaft (figure B) AIN CRANKSHAFT JOURNAL DIAMETER Specification Desc./Quantity Class 1 Diameter: 40.004-40.012 mm (1.5750-1.5753 in) Class 2 Diameter: 40.013-40.020 mm (1.5753-1.5756 in) Class 3 Diameter: 43.007-43.015 mm (1.6932-1.6935 in) Class 4 Diameter: 43.016-43.023 mm (1.6935-1.6937 in)
Page 62: Removing The Head Cover
Engine V85 E4 Engine • (1-2) according to main journal diameter on alternator side. • (3-4) according to main journal diameter on clutch side. SELECTING CRANKSHAFT - CRANKCASE BUSHING CLASSES Crankcase class Class 1 crankshaft Class 2 crankshaft Class 3 crankshaft...
Page 63: Removing The Cylinder Head
Engine V85 E4 Engine • Check that the mating faces that contact the heads are not damaged or blistered Removing the cylinder head NOTE THE HEAD REMOVAL OPERATIONS REFER TO ONE HEAD BUT APPLY TO BOTH • Remove the head cover •...
Page 64 Engine V85 E4 Engine • Remove the rocker pin retainer fork • Remove the rocker pin CAUTION THE INTAKE VALVE IS CHARACTERIZED BY THE PRES- ENCE OF A CALIBRATED PAD, THEREFORE PAY PAR- TICULAR ATTENTION TO RECOVER IT DURING DISAS- SEMBLY.
Page 65 Engine V85 E4 Engine • Remove the rocker rods • Remove the nut with relevant washer of the cylinder to the crankcase • Unscrew and remove the compensa- tion nut of the cam tower • Undo and remove the fastening nuts of...
Page 66 Engine V85 E4 Engine • Remove the cam tower • Remove the three rubber O-Rings CAUTION PAY SPECIAL ATTENTION THAT THE O-RINGS DO NOT ACCIDENTALLY FALL INTO THE PROCESSING HOLES OF THE ROCKERS RODS • Remove the complete head •...
Page 67: Cylinder Head
Engine V85 E4 Engine • Undo and remove the engine oil pres- sure sensor NOTE ONLY FOR E4 VEHICLES • Undo and remove the secondary air valve cover • Remove the secondary air valve • check and if necessary replace the ex- ternal rubber gasket •...
Page 68: Removing The Valves
Engine V85 E4 Engine Removing the valves • Place the special tool on the upper cap of the valve to be removed and at the centre of the head of the valve. Specific tooling 020382Y Tool to extract valve cotters •...
Page 69: Checking The Rocker Arms
Engine V85 E4 Engine • Remove the valve from the head • Remove the gasket of the valve guide VALVE GUIDES MUST BE REPLACED WHEN THEY ARE WORN TO THE POINT THAT REPLACING THE VALVE ALONE IS NOT ENOUGH TO ELIMINATE CLEARANCE BE- TWEEN VALVE STEM AND VALVE GUIDE BORE.
Page 70: Inspecting The Springs And Half-Cones
Engine V85 E4 Engine Intake valves: Characteristic Coupling clearance between valve and guide (WEAR LIMIT) 0.05 mm (0.0020 in) Valve stem distortion (MEASURED ON 45°) 0.03 mm (0.0012 in) Valve stem diameter (MINIMUM WEAR VALUE) 5.95 mm (0.2342 in) Valve head eccentricity (MAXIMUM ALLOWED VALUE) 0.05 mm (0.0020 in)
Page 71: Adjusting Valve Clearance
Engine V85 E4 Engine Adjusting valve clearance • Bring the piston of the left cylinder to top dead centre making sure that the reference mark on the crankshaft gear and on the timing system shaft are aligned. NOTE PROCEDURE VALID ONLY FOR E4 VEHICLES •...
Page 72 Engine V85 E4 Engine • Loosen the lock nut, adjust the clear- ance by acting on the adjuster until reaching the prescribed values • Tighten the lock nut Timing Rimozione ruota fonica NOTE PROCEDURE VALID ONLY FOR E4 VEHICLES •...
Page 73: Removing The Chain Tensioner
Engine V85 E4 Engine Removing the chain tensioner • Remove the timing system cover • Remove the flywheel • Remove the chain tensioner fixing screw recovering the washer • Remove the chain tensioner Chain removal • Remove the timing system cover, the rotor and the tone wheel.
Page 74: Removing The Camshaft
Engine V85 E4 Engine • Remove the 3 fixing screws of the tim- ing system sprocket and retrieve the front chain guide cap. NOTE ONLY FOR E5 VEHICLES • Remove the fixing screw with relative washer for the oil pump gear.
Page 75 Engine V85 E4 Engine • Remove the timing system cover, the rotor, the tone wheel, the timing system with gear and the blow-by cap. • Remove the two fixing screws of the camshaft. • Remove the camshaft extracting it from the crankcase.
Page 76: Installing The Camshaft
Engine V85 E4 Engine • Remove the camshaft extracting it from the crankcase and retrieve the fix- ing flange. Installing the camshaft NOTE PROCEDURE VALID ONLY FOR E4 VEHICLES • Insert the camshaft into the crankcase. • Place the two fixing screws and tighten them to the prescribed torque.
Page 77 Engine V85 E4 Engine • Place the two fixing screws and tighten them to the prescribed torque. • Place the bucket tappets paying atten- tion to the centring pin. Apply grease ensuring that it does not fall. Installazione piattello blow-by •...
Page 78: Cam Timing
Engine V85 E4 Engine • Fit the tone wheel checking the correct positioning on the camshaft, using the centring plug • Insert the screw complete with washer to fasten the tone wheel and tighten it to the prescribed torque. Cam timing Timing •...
Page 79 Engine V85 E4 Engine CAUTION CHECK THE CORRECT INSTALLATION USING THE ALIGNMENT OF THE REFERENCE NOTCHES ON THE CRANKSHAFT AND ON THE TIMING SYSTEM GEAR • Using a thin tool, refine the alignment of the oil pump pin with the milling on the gear of the pump itself.
Page 80 Engine V85 E4 Engine • Position the three fixing screws of the timing gear and tighten to the prescri- bed torque. NOTE ONLY FOR E4 VEHICLES • Position the tone wheel and after in- serting the fixing screw with washer, tighten to the prescribed torque.
Page 81: Removing The Cylinder
Engine V85 E4 Engine Removing the cylinder • Slide off the cylinder from the stud bolts. • Remove the temperature sensor from the left cylinder. NOTE ONLY FOR E5 VEHICLES • Remove the gasket from the stud bolts Disassembling the piston •...
Page 82: Checking The Cylinder
Engine V85 E4 Engine • Before removing the pin, check the mounting clearance between pin and piston. Replace it if the value is out of the limits • Slide off the pin Characteristic Mounting clearance between piston and pin 0.01 mm (0.0004 in) •...
Page 83: Checking The Piston
Engine V85 E4 Engine Type Allowed diameter Assembly clearance between piston and cylinder 84.007-84.014 mm (3.3074-3.3076 in) 0.040-0.054 mm (0.0016-0.0021 in) 84.014-84.021 mm (3.3076-3.3079 in) 0.040-0.054 mm (0.0016-0.0021 in) 84.021-84.028 mm (3.3079-3.3082 in) 0.040-0.054 mm (0.0016-0.0021 in) Checking the piston •...
Page 84: Inspecting The Piston Rings
Engine V85 E4 Engine Inspecting the piston rings • Clean off any carbon deposits from the grooves in the piston rings and from the rings themselves. • Measure the piston ring side clearance and replace the piston and the piston rings all together if not complying with specifications.
Page 85: Installing The Cylinder
Engine V85 E4 Engine • Insert the pin • Insert the retainer ring Installing the cylinder • Check that the piston ring end gaps are approximately 120 degrees from each other. • Fit a new gasket • Fit the existing temperature sensor on- ly on the left cylinder.
Page 86 Engine V85 E4 Engine • Place the appropriate ring clamp on the piston • Place the cylinder so that the piston correctly enters the seat and as soon as the segments zone is exceeded re- move the ring clamp Specific tooling 020128Y Piston fitting ring •...
Page 87: Installing The Cylinder Head
Engine V85 E4 Engine Installing the cylinder head • Insert the flame trap of the secondary air valve • Insert the reed valve • Fit the cover of the secondary air valve and tighten the screws to the prescri- bed torque •...
Page 88 Engine V85 E4 Engine • Place the gasket • Place engine head into place • Place the three rubber O-Rings, par- ticularly apply grease to the O-Ring that will be inserted in the stud bolt in order to avoid damaging it •...
Page 89 Engine V85 E4 Engine • Following a cross order "A-C-B-D" screw the fixing nuts of the cam tower to the prescribed torque • Insert and tighten the compensation nut of the cam tower to the prescribed torque • Position the washer with the relevant nut on the base of the cylinder and tighten to the prescribed torque.
Page 90 Engine V85 E4 Engine CAUTION PRIOR TO POSITIONING THE ROCKERS, CHECK THAT THE CALIBRATED PAD ON THE INTAKE VALVE IS INSER- TED. • Place the rocker in its seat by inserting the Belleville spring at the same time • Using the rocker shim centring pin, align the rocker and the Belleville spring with the pin seat...
Page 91 Engine V85 E4 Engine • Insert and tighten the fixing screw of the rocker pin lock fork to the prescri- bed torque • Insert and tighten the spark plug to the prescribed torque Installing the head cover • Fit the gasket on the head cover •...
Page 92: Crankcase - Crankshaft
Engine V85 E4 Engine • Place the cover fixing screws and tight- en them to the prescribed torque Crankcase - crankshaft Splitting the crankcase halves • Remove the bucket tappets, the oil sump, the filter and the overpressure valve. •...
Page 93: Removing The Crankshaft
Engine V85 E4 Engine • Remove the upper crankcase being careful not to damage its mating face • Remove the crankshaft together with connecting rods and small ends Removing the crankshaft • Remove the crankshaft connecting rods. • Unscrew the oil plug and thoroughly clean the oilway and oil passages delivering oil to con- necting rods and main journals.
Page 94: Inspecting The Crankcase Halves
Engine V85 E4 Engine • Remove the small ends from the con- necting rods. CAUTION REPEAT THE PROCEDURE FOR THE OTHER CONNECT- ING ROD Inspecting the crankcase halves • Check that the mating faces are not damaged, dented or scored. Remove the liquid gasket residues.
Page 95: Checking The Connecting Rod
Engine V85 E4 Engine Checking the connecting rod • Check using a micrometer the measure of the connecting rod pin orthogonal axes an in the working area of the small ends, check the measure of the small ends seats on the timing system side and on the flywheel side.
Page 96 Engine V85 E4 Engine ONNECTING ROD HEAD BUSHING CLASSES Selection class Thickness 1.807-1.811 mm (0.0711-0.0713 in) Blue 1.811-1.815 mm (0.0713-0.0715 in) Yellow 1.815-1.819 mm (0.0715-0.0716 in) ONNECTING ROD CRANKSHAFT CLASSES Selection class Connecting rod big end diameter Crankshaft diameter A (light blue) 43.657-43.664 mm (1.7188-1.7191 in)
Page 97: Installing The Crankshaft
Engine V85 E4 Engine • Before assembly, take careful note of the coupling classes. • Reassemble the connecting rods in the crankshaft seat on the crankpin by screwing the screws with the correct tightening sequence specified in the "characteristics" chapter, "tightening torque / engine"...
Page 98: Refitting The Crankcase Halves
Engine V85 E4 Engine Refitting the crankcase halves • Insert the small ends timing system side and flywheel side on both crank- cases paying attention to lubricate them • With the help of grease, place the thrusts on the upper crankcase from the flywheel side,...
Page 99 Engine V85 E4 Engine • Grasp the crankshaft assembly with the upper crankcase keeping the two components together, rotate them and lay them on the lower crankcase. • Insert and screw the four long nuts and the six external nuts together with washers..
Page 100 Engine V85 E4 Engine • Remove the cover (1) from the pump (2). • Working on the oil pump gear side, re- move the external rotor (3). • Remove the internal rotor (4). • Remove the safety pin (5) from the pump drive shaft.
Page 101 Engine V85 E4 Engine • Working from the opposite side of the oil pump, extract the pump drive shaft (6) removing the internal rotor (7) and the external rotor (8). Inspection OIL PUMP BODY Check that the faces and inner seats of the oil pump body are not scored, damaged or dented.
Page 102 Engine V85 E4 Engine INTERNAL ROTOR ( CRANKCASE SIDE) Description Values External diameter (MAXIMUM WEAR VALUE) 29.749 mm (0.1712 in) Internal diameter (MAXIMUM WEAR VALUE) 12.018 mm (0.4731 in) Thickness (MINIMUM WEAR VALUE) 13.97 mm (0.5500 in) OIL PUMP DRIVE SHAFT Check shaft and thread for damage;...
Page 103 Engine V85 E4 Engine • Insert the internal rotor (5) paying at- tention that the pin enters the machin- ing seat. • Insert the external rotor (6) paying at- tention to the punch mark that must be facing outwards. •...
Page 104 Engine V85 E4 Engine Removing the oil sump • Remove the engine oil filter fixing screw • Remove the engine oil filter • -Remove the 14 fastening screws of the oil sump • Remove the oil sump ENG - 104...
Page 105 Engine V85 E4 Engine • Remove the gasket • Remove the rose pipe • Remove the cap and the relative cop- per gasket • Remove the spring ENG - 105...
Page 106 Engine V85 E4 Engine • Remove the overpressure valve Refitting the oil sump • Install the overpressure valve in the engine crankcase • Insert the spring and afterwards the cap provided with a new copper gas- ket, tighten it to the prescribed torque •...
Page 107 Engine V85 E4 Engine • Place the gasket and insert the oil sump cover • Insert and tighten the 14 fastening screws of the oil sump to the prescri- bed torque • Insert the engine oil filter together with the cover •...
Page 108 Chain: 73 Chain tensioner: 73 Clutch: 39, 41, 53, 54, 56, 57 Crankcase: 92, 94, 98 Crankshaft: 92–94, 97 Cylinder: 63, 67, 81, 82, 85, 87 Desmodromic drum: 41 Forks: 41 Head cover: 62, 91 Magneto flywheel: Oil sump: 103, 104, 106 Pistons: Primary shaft: 29 Secondary air system:...

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