MOTO GUZZI V100 E5 2023 Service Station Manual
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MOTO GUZZI V100 E5 2023 Service Station Manual

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Table of Contents

SERVICE STATION MANUAL
2Q000541
V100 E5

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Summary of Contents for MOTO GUZZI V100 E5 2023

  • Page 1 SERVICE STATION MANUAL 2Q000541 V100 E5...
  • 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 CLU SYS LUTCH SYSTEM COOL SYS OOLING SYSTEM BODYW ODYWORK...
  • Page 6 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 7 V100 E5 Pre-delivery Carry out the listed tests before delivering the vehicle. WARNING PROCEED WITH THE UTMOST CAUTION WHEN HANDLING PETROL. 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 V100 E5 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 V100 E5 Pre-delivery TRADITIONAL BATTERY ACTIVATION PRO- CEDURE • Place the battery on a flat surface. • Remove the cell's protective sticker. • Take the acid container. • Remove the cap 1 of the container 2. • Place the container upside down, per- pendicularly above the battery, align- ing the outlets with the battery cells.
  • Page 10 V100 E5 Pre-delivery After performing the battery activation procedure, install it on the vehicle in the dedicated compart- ment. Then connect the cables to the battery, starting from the positive (1). Install the battery cover (2) and tighten the fixing screws (3).
  • Page 11 V100 E5 Pre-delivery Do not leave the vehicle with the engine off and the ignition key to "ON". The sophisticated on- board instruments have a high current draw which, if left on with the engine switched off, will discharge the battery in a short time. Static test Static control after the test drive: •...
  • Page 12 V100 E5 Pre-delivery Do not leave the vehicle with the engine off and the ignition key to "ON". The sophisticated on- board instruments have a high current draw which, if left on with the engine switched off, will discharge the battery in a short time. Specific operations for the vehicle UNPACKING CAUTION...
  • Page 13 V100 E5 Pre-delivery CAUTION LIFT THE CARDBOARD COVER VERTICALLY, DO NOT ROTATE OR TILT IT AND TAKE EXTRA CARE NOT TO DAMAGE THE VEHICLE WHEN LIFTING IT. • Store the cardboard cover away from the vehicle. • Check the integrity of the footrest and ensure that the vehicle is free from dents and/or scratches.
  • Page 14 V100 E5 Pre-delivery • Then remove the front retaining straps. CAUTION DO NOT REMOVE THE VEHICLE FROM THE WOODEN PLATFORM AT THIS TIME. • Using suitable tools, remove the front cross member of the wooden platform. • Making sure that the platform remains stationary, lower the vehicle from the front of the wooden platform, support- ing it by the handlebar and the rear...
  • Page 15 V100 E5 Pre-delivery • Remove the protective bags of the two cylinders. • Install the battery according to the op- erations described in the section "Body - Battery". • Install the rear-view mirrors. FITTING THE REAR-VIEW MIRRORS • Screw the mirror into the clutch master cylinder (left) or front brake master cyl- inder (right) support.
  • Page 16 INDEX OF TOPICS CHAR HARACTERISTICS...
  • Page 17 V100 E5 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 18 V100 E5 Characteristics KEEP OUT OF THE REACH OF CHILDREN. NEVER REMOVE THE RADIATOR CAP WHILE THE ENGINE IS STILL HOT. COOLANT IS UNDER PRESSURE AND MAY CAUSE BURNS. Used engine oil and transmission oil CAUTION WHEN CARRYING OUT MAINTENANCE OPERATIONS, IT IS ADVISABLE TO WEAR PROTEC- TIVE IMPERMEABLE GLOVES.
  • Page 19 CAUTION THE BEARING MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE THEY MUST BE REPLACED. • Only use ORIGINAL Moto Guzzi SPARE PARTS. • Always use the recommended lubricants and consumable material. • Lubricate the parts (when possible) before reassembling them.
  • Page 20 V100 E5 Characteristics • If there is dirt, rust, moisture, etc., carefully clean the inside of the connector using pressur- ised air. • Ensure that the cables make correct contact with the terminals inside the connectors. • Then plug in the two connectors, ensuring correct coupling (if the specific catches are present, you will hear a typical "click").
  • Page 21 V100 E5 Characteristics 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 22 V100 E5 Characteristics Specification Desc./Quantity Maximum width 835 mm (32.87 in) Height (adjustable at the windshield) 1210 - 1300 mm (47.63 - 51.18 in) Wheelbase 1475 mm (58.07 in) Kerb weight 233 kg (513.68 lb) Engine ENGINE Specification Desc./Quantity Type Four-stroke, 90°...
  • Page 23 V100 E5 Characteristics Electrical system ELECTRICAL SYSTEM Specification Desc./Quantity Battery 12 V - 12 Ah Fuses 40- 30 - 20 - 15 (3) - 10 (2) - 7.5 (6) - 5 (3) - 3 A Permanent magnet alternator 12V - 550W BULBS Specification Desc./Quantity...
  • Page 24 V100 E5 Characteristics Brakes BRAKES Specification Desc./Quantity Front two 320 mm (12.59 in) diam. stainless steel floating discs, cal- liper with 4 32 mm (1.26 in) diam. counteracting plungers Rear 280 mm (11.02 in) stainless steel disc, floating calliper with two 28 mm (1.10 in) diameter pistons Wheels and tyres RIMS AND WHEELS...
  • Page 25 V100 E5 Characteristics Front side OP FAIRING Pos. Description Type Quantity Torque Notes Fixing screw for actuator connecting SWP 5x30 1 ± 0.3 Nm (1.11 ± 0.22 lb ft) Fixing screw for actuator Self-tapping 2.5 ± 0.3 Nm (1.84 ± 5.1x18 0.22 lb ft) Fixing screw for actuator assembly...
  • Page 26 V100 E5 Characteristics RONT FAIRING Pos. Description Type Quantity Torque Notes Fixing screw for front spoiler 4 ± 0.8 Nm (2.95 ± 0.59 lb ft) Fixing screw for side fairing to spoiler 4 ± 0.8 Nm (2.95 ± 0.59 lb ft) Upper front fixing screw 4 ±...
  • Page 27 V100 E5 Characteristics NSTRUMENTS Pos. Description Type Quantity Torque Notes Fixing screw for TFT instrument pan- SWP 4.9 3 ± 0.5 Nm (2.21 ± 0.37 lb ft) Instrument panel bracket fastening 10 ± 2 Nm (7.38 ± 1.48 Screw and nut lb ft) EADLAMP Pos.
  • Page 28 V100 E5 Characteristics ANDLEBAR ONTROLS Pos. Description Type Quantity Torque Notes Screws fastening the lower U-bolts to 50 Nm (36.88 lbf ft) Loctite 243 the upper steering yoke Screws fastening the lower U-bolt 25 Nm (18.44 lbf ft) clamp to the handlebar Screws fastening the anti-vibration 10 Nm (7.38 lbf ft) weights to the handlebar...
  • Page 29 V100 E5 Characteristics LUTCH CONTROL Pos. Description Type Quantity Torque Notes Actuator fixing screw to clutch crank- 10 ± 2 Nm (7.38 ± 1.48 case lb ft) Fixing screw for clutch lever U-bolt 10 ± 1.5 Nm (7.38 ± 1.11 lb ft) CHAR - 29...
  • Page 30 V100 E5 Characteristics IRRORS Pos. Description Type Quantity Torque Notes Fixing nut for mirror bracket 4 ± 0.5 Nm (2.95 ± 0.37 lbf ft) TEERING Pos. Description Type Quantity Torque Notes Ring nut fastening the bottom yoke/ First tightening tor- steering pin assembly to the head- que 60 Nm (44.25 stock...

  • Page 31: Table Of Contents

    V100 E5 Characteristics NTAKE ASSEMBLY Pos. Description Type Quantity Torque Notes Fixing screw for intake ducts to throt- 10 ± 1.5 Nm (7.38 ± 1.11 tle bodies lb ft) Fixing screws for air filter and filter SWP 4.9 3 ± 0.5 Nm (2.21 ± 0.37 case cover lbf ft) Intake duct fastening to filter case...

  • Page 32: Pos

    V100 E5 Characteristics COOLING SYSTEM Pos. Description Type Quantity Torque Notes Upper radiator fixing screw 7 ± 1.5 Nm (5.16 ± 1.10 lb ft) Lower radiator fixing nut 7 ± 1.5 Nm (5.16 ± 1.10 lb ft) Fixing nut for electrical fan to radiator 0.5 ±...
  • Page 33 V100 E5 Characteristics RONT WHEEL Pos. Description Type Quantity Torque Notes Nut fastening the front wheel axle M25x1.5 80 Nm (59.01 lbf ft) Brake disc fixing screw 6 + 6 30 Nm (22.13 lbf ft) Loctite 243 ABS sensor fixing screw 6 Nm (4.46 lbf ft) CHAR - 33...
  • Page 34 V100 E5 Characteristics RONT BRAKE MASTER CYLINDER Pos. Description Type Quantity Torque Notes Screws fixing brake pump clamp to 10 ± 1.5 Nm (7.38 ± 1.11 the handlebar lb ft) RONT BRAKE CALLIPER Pos. Description Type Quantity Torque Notes Screws fastening front brake calliper M10x1.25 50 ±...

  • Page 35: Nm (4.23 ± 0.74 Lb Ft)

    V100 E5 Characteristics Central part UEL TANK COVER Pos. Description Type Quantity Torque Notes Screw for filter case cover 4 ± 0.8 Nm (2.95 ± 0.59 lb ft) Fixing screw for tank cover 4 ± 0.8 Nm (2.95 ± 0.59 lb ft) Fixing screw for side fairing to tank 4 ±...

  • Page 36: Type Quantity M6

    V100 E5 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 Nuts fixing the fuel level probe to the 1 Nm (0.74 lb ft) fuel tank CHAR - 36...

  • Page 37: Type Quantity

    V100 E5 Characteristics HASSIS Pos. Description Type Quantity Torque Notes Rear fixing screw for motor to chas- M10 x 1.25 50 ± 7.5 Nm (36.88 ± 5.53 lbf ft) Side fixing screw for motor to chassis 50 ± 7.5 Nm (36.88 ± 5.53 lbf ft) ANISTER SYSTEM Pos.
  • Page 38 V100 E5 Characteristics OOTRESTS Pos. Description Type Quantity Torque Notes Fixing screw for the right footboard 25 ± 3.5 Nm (18.44 ± 2.58 lbf ft) Fixing screw for the left footboard 25 ± 3.5 Nm (18.44 ± 2.58 lbf ft) Fixing screw for the left footboard 25 ±...

  • Page 39: Torque Notes 10 ± 1.5 Nm

    V100 E5 Characteristics EAR BRAKE MASTER CYLINDER Pos. Description Type Quantity Torque Notes Rear brake rod lock nut 6 ± 1 Nm (4.23 ± 0.74 lb Rear brake pump fastening screws 10 ± 1.5 Nm (7.38 ± 1.11 lb ft) Brake oil tank fixing screw 6 ±...
  • Page 40 V100 E5 Characteristics TAND Pos. Description Type Quantity Torque Notes Nut for fastening the stand to the 25 ± 3.5 Nm (18.44 ± stand plate 2.58 lb ft) Stand switch lock pin 10 ± 2 Nm (7.38 ± 1.48 Pre-applied Loct. lb ft) Pin fastening the spring to the stand 25 ±...
  • Page 41 V100 E5 Characteristics OCKS Pos. Description Type Quantity Torque Notes Fixing screw for ignition lock (RH Manual Breaking the screw side) head Fixing screw for ignition lock (LH 25 ± 3.5 Nm (18.44 ± side) 2.58 lb ft) Fixing screw for saddle mounting 10 ±...
  • Page 42 V100 E5 Characteristics Back side REAR WHEEL TRANSMISSION Pos. Description Type Quantity Torque Notes Screw fixing gearcase to swingarm 45 ± 6.75 Nm (33.2 ± 5 lb ft) CHAR - 42...
  • Page 43 V100 E5 Characteristics REAR WHEEL TRANSMISSION - COMPONENTS Pos. Description Type Quantity Torque Notes Fixing screw for rear gearbox cover M8x1 25 Nm (18.43 lb ft) Screws with pre-ap- plied threadlocker Pinion fixing ring nut 140 Nm (103.25 lb ft) With Loctite 243 Flanged nut fixing pinion M20x1...
  • Page 44 V100 E5 Characteristics UNDER-SEAT COMPARTMENT Pos. Description Type Quantity Torque Notes Rear storage compartment fixing 4 ± 0.8 Nm (2.95 ± 0.59 screw lb ft) Fixing screw for lower saddle mount- 4 ± 0.8 Nm (2.95 ± 0.59 ing closure lb ft) CHAR - 44...
  • Page 45 V100 E5 Characteristics REAR WHEEL Pos. Description Type Quantity Torque Notes Rear wheel nut M60x2 260 ± 39 Nm (191.75 ± 28.76 lb ft) Rear brake disc fixing screw 30 ± 4.5 Nm (22.12 ± Screws with pre-ap- 3.32 lb ft) plied threadlocker CHAR - 45...

  • Page 46: Torque Notes 50 ± 5 Nm

    V100 E5 Characteristics REAR BRAKE CALLIPER Pos. Description Type Quantity Torque Notes Rear brake calliper fixing screw 50 ± 5 Nm (36.87 ± 3.7 With a torque lb ft) wrench CHAR - 46...
  • Page 47 V100 E5 Characteristics REAR MUDGUARD Pos. Description Type Quantity Torque Notes Fixing screw for centre rear cover 4 ± 0.8 Nm (2.95 ± 0.59 lb ft) License plate holder fixing screw 5.5 ± 1.1 Nm (4.1 ± 0.8 lb ft) Fixing screw for lower licence plate SWP 4.9 3 ±...
  • Page 48 V100 E5 Characteristics REAR BODYWORK Pos. Description Type Quantity Torque Notes Fixing screw for passenger grab han- 34 ± 5 Nm (25.1 ± 3.7 lb Screws with pre-ap- plied threadlocker Fixing screw for rear side covers 4 ± 0.8 Nm (2.95 ± 0.59 lb ft) Front fixing screw for luggage holder 34 ±...
  • Page 49 V100 E5 Characteristics SILENCER Pos. Description Type Quantity Torque Notes Screw fastening outer silencer sup- 25 ± 5 Nm (18.43 ± 3.68 port bracket lb ft) Upper silencer fixing screw to the 10 ± 2 Nm (7.37 ± 1.47 footrest lb ft) Lower silencer fixing screw to the 25 ±...
  • Page 50 V100 E5 Characteristics REAR SHOCK ABSORBER Pos. Description Type Quantity Torque Notes Upper shock absorber fixing screw 50 ± 7.5 Nm (36.87 ± 5.53 lb ft) Lower shock absorber clamping 50 ± 7.5 Nm (36.87 ± screw 5.53 lb ft) Fixing screw for preload tank to 10 ±...
  • Page 51 V100 E5 Characteristics REAR ELECTRICAL SYSTEM Pos. Description Type Quantity Torque Notes Fixing screw for battery cover to 4 ± 0.8 Nm (2.95 ± 0.59 chassis lb ft) Fixing screw for ECU holder SWP 4.9 3 ± 0.45 Nm (2.2 ± 0.33 lb ft) Fixing screw for IMU ECU to lower 7 ±...
  • Page 52 INDEX OF TOPICS S-TOOLS PECIAL TOOLS...
  • Page 53 V100 E5 Special tools SPECIAL TOOLS Stores code Description 020851Y Camshaft timing pin 020382Y Valve cotters equipped with part 012 re- moval tool 020853Y Compresses intake valve springs 020376Y Adaptor handle 020360Y 52 x 55 mm adaptor 020714Y Dial gauge mount S-TOOLS - 53...
  • Page 54 V100 E5 Special tools Stores code Description 020888Y Pre-load tube clamp 020922Y Diagnostic tool 021017Y OBD cable for E5 vehicles 021058Y Clutch retainer 021059Y Primary retainer 021061Y Ring clamp 021062Y Crankshaft support U-bolt S-TOOLS - 54...
  • Page 55 V100 E5 Special tools Stores code Description 021063Y Water pump seal insertion tool 021064Y Large pin for engine timing 021065Y Engine support frame 021066Y Gearbox mounting 021067Y Pinion side fixing ring nut socket 021068Y Ring gear side roller cage extraction punch 021069Y 52 mm adaptor for single arm lift stand...
  • Page 56 V100 E5 Special tools Stores code Description 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 021072Y Right chain tensioner 021073Y Central chain tensioner S-TOOLS - 56...
  • Page 57 V100 E5 Special tools Stores code Description 021074Y Left chain tensioner 01761-04 Ohlins fork cap ring nut Commercially available tool Bushing of 65 mm S-TOOLS - 57...
  • Page 58 INDEX OF TOPICS MAIN AINTENANCE...
  • Page 59 V100 E5 Maintenance Scheduled maintenance table NOTE CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VE- HICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS, OFF ROAD OR FOR TRACK USE. NOTE THE TIMES LISTED ON THE SCHEDULED MAINTENANCE TABLE INCLUDE TIME DEDICATED TO MANAGEMENT ACTIVITIES.
  • Page 60 V100 E5 Maintenance km x 1,000 (mi x 1,000) EVERY EVERY (0.9) (7.5) (14.9) (22.4) (29.8) (37.3) (44.7) MONTH MONTH 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. ENSURE THAT THE VEHICLE CALIBRATION IS UP TO DATE AFTER UPDATING THE DIAGNOS- TIC TOOL.
  • Page 61 V100 E5 Maintenance km x 1,000 (mi x 1,000) 1,5 (0.9) 12 (7.5) 24 (14.9) 36 (22.4) 48 (29.8) 60 (37.3) 72 (44.7) 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. ENSURE THAT THE VEHICLE CALIBRATION IS UP TO DATE AFTER UPDATING THE DIAGNOS- TIC TOOL.
  • Page 62 V100 E5 Maintenance • Remove the spark plug cover (2). • Release the cable from their seats on the valve cover. • Remove the fixing screw (3) of the coil. • Extract the coil (4) from the head. MAIN - 62...
  • Page 63 V100 E5 Maintenance • Using a dedicated wrench, unscrew the spark plug and remove it from the head. • Check the state of wear of the spark plug and measure the distance be- tween the electrodes. • If the value does not lie within the specified value, replace the spark plug with a new one.
  • Page 64 V100 E5 Maintenance Loosen the drain plug without removing it. Unscrew and remove the filler plug (2). Completely unscrew and remove the drain plug. Drain the oil into the container for at least 5 mi- nutes for oil to drain out completely. Once the oil has drained out, screw in and tighten the drain plug with its washer to the prescribed torque.
  • Page 65 V100 E5 Maintenance Using a special syringe, fill in with new oil through the filler cap. CAUTION 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. Recommended products 75W-140 lubricant for gearboxes and transmis- sions Synthetic lubricant for gearboxes and...
  • Page 66 V100 E5 Maintenance it and blow it with compressed air to carefully re- move any oil residues. CAUTION DURING REPLACEMENT, USE A NEW SEALING WASHER FOR THE BREATHER CAP. Engine oil Check Check the engine oil level frequently. NOTE CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VE- HICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS, OFF ROAD OR FOR TRACK USE.
  • Page 67 V100 E5 Maintenance AN OIL LEVEL NOT WITHIN THE MINIMUM AND MAXIMUM MARKINGS MAY CAUSE SEVERE ENGINE DAMAGE. Replacement NOTE HOT OIL IS MORE FLUID AND WILL DRAIN OUT MORE EASILY AND COMPLETELY. Place a collection container of suitable capacity under the drain plug (1).
  • Page 68 V100 E5 Maintenance Once the oil has drained out, screw in and tighten the drain plug with its washer to the prescribed torque. Remove metal residues attached to the drain plug magnet. NOTE DURING REPLACEMENT, USE A NEW SEALING WASHER. DO NOT DISPOSE OF OIL IN THE ENVIRONMENT.
  • Page 69 V100 E5 Maintenance Engine oil filter Loosen the 3 screws securing the engine oil filter cover. Place a container with adequate collecting capaci- ty at the engine oil filter cover and completely unscrew the 3 fixing screws. DO NOT DISPOSE OF OIL IN THE ENVIRONMENT. DISPOSE OF ENGINE OIL IN A SEALED CONTAINER AND TAKE IT TO YOUR SUPPLIER OR TO THE NEAREST USED OIL COLLECTION CENTRE.
  • Page 70 V100 E5 Maintenance When reassembling, use a new O-ring seal for the engine oil filter cover. Insert the new engine oil filter. NOTE NEVER REUSE AN OLD FILTER. Refit the cover with the spring facing downwards. Screw in and tighten the 3 fixing screws for the engine oil filter cover to the prescribed torque.
  • Page 71 V100 E5 Maintenance Air filter REMOVAL • Remove the four fixing screws and then remove the cover (1) of the tank. • Remove the four fixing screws and then remove the cover (2) of the filter box. • Remove the two fixing screws indica- ted in the figure.
  • Page 72 V100 E5 Maintenance • Remove the air filter (4) from the filter box. Air filter housing Air filter housing removal • First remove the fuel tank. • Loosen the two clamps (1) of the throt- tle body manifolds. • Open the clamp and disconnect the left breather pipe (2) from the filter box.
  • Page 73 V100 E5 Maintenance • Open the clamp and disconnect the right breather pipe (3) from the filter box. • Remove the right fixing screw of the fil- ter box. • Remove the filter box from the vehicle by extracting it upward. DURING REASSEMBLY, ENSURE THE CORRECT INSER- TION OF THE AIR FILTER HOUSING MANIFOLDS ON THE THROTTLE BODIES.
  • Page 74 V100 E5 Maintenance Checking the valve clearance • Install a workshop stand to the rear wheel of the vehicle so as to lift it from the ground. • Remove the spark plugs from both heads. • Turn the rear wheel until the left-hand piston is at top dead centre (TDC) and in compression (all cams facing up and with the lobes converging).
  • Page 75 V100 E5 Maintenance • Repeat the operation for the remaining valves. If the valve clearance is not within the tolerance range, adjust the valve clearance as shown below. • Turn the rear wheel and bring the right- hand piston to TDC and in compres- sion (the lobes of the camshafts must face upwards and diverge from each other, as shown in the figure).
  • Page 76 V100 E5 Maintenance • Check that the cam lobes are divergent from each other. • Insert the special tool (1) into the hole on the exhaust camshaft. Specific tooling 021064Y Large pin for engine timing • Continue to insert the tool (1) to inter- cept the hole on the intake manifold.
  • Page 77 V100 E5 Maintenance • Remove the fixing screws of the upper mounting, following the sequence A-B- C-D-E-F-G-H- I. • Remove the upper mounting (2) from the head. • Remove the tool (1) from the cam- shafts, taking care that the chain ten- sioner, still loaded with oil, does not cause the shafts to drop from the head.
  • Page 78 V100 E5 Maintenance • Remove the exhaust camshaft (4). • Fasten the timing chain to the vehicle, taking care that it does not get out of the sprocket on the service shaft. • Lift the rocker arm of the valve(s) to be adjusted.
  • Page 79 V100 E5 Maintenance • After replacing the pad(s), install the intake shaft (3) on the timing chain, so that the sprocket and the chain marks coincide, then position it in its seat on the head. • Install the exhaust shaft (4) on the tim- ing chain, by aligning the references the sprocket and chain, then place it in its seating on the head.
  • Page 80 V100 E5 Maintenance • Tighten the fixing screws to the speci- fied torque, following the sequence A- B-C-D-E-F-G-H- I. Locking torques (N*m) Camshaft support screw 11-13 Nm (8.11 - 9.59 lbf ft) NOTE The screw (6) in the hole of the spark plug has a washer, while the screw (7) is the single shorter screw compared to the others.
  • Page 81 V100 E5 Maintenance LH HEAD To adjust the valves of the LH head, follow the procedures for the RH head but with the difference • Turn the engine COUNTER-CLOCK- WISE and bring the LH piston to Top Dead Centre. NOTE THE HOLE ON THE PINION MARKED "PMS SX"...
  • Page 82 V100 E5 Maintenance Top-up • Remove the expansion tank cap. • Top up with the recommended fluid, to reach a level between the notch "MIN" and "MAX"of the expansion tank, visi- ble from the right side of the vehicle behind the steering headstock. Braking system Level check FRONT BRAKE...
  • Page 83 V100 E5 Maintenance REAR BRAKE • Keep the vehicle upright so that the flu- id in the reservoir is at the same level as the plug. • Make sure that the fluid level in the res- ervoir is above the "MIN" reference mark: MIN = minimum level MAX = maximum level...
  • Page 84 V100 E5 Maintenance SAE J 1703; FMVSS 116; ISO 4925; CUNA NC 956 DOT4 Front braking system • Use a short Philips screwdriver, un- screw the screws (1) of the front brak- ing system fluid tank (2). • Lift and remove the cover (3) and screws (1) as well.
  • Page 85 V100 E5 Maintenance ONLY FILL TO THE "MAX" LEVEL AFTER FITTING NEW BRAKE PADS. DO NOT FILL TO THE "MAX" LEVEL WITH WORN PADS, AS THIS WILL CAUSE FLUID TO ESCAPE WHEN REPLACING BRAKE PADS. CHECK BRAKING EFFICIENCY. IF THE DEAD ZONE OF THE BRAKE PEDAL OR BRAKE LEVER IS TOO LONG, OR IN CASE OF FLUID LOSS, IT MAY BE NECESSARY TO BLEED THE AIR TRAPPED IN THE SYSTEM.
  • Page 86 V100 E5 Maintenance To quickly check if the headlamp is aimed correct- ly, place the vehicle on a level surface 10 m (32.8 ft) from a vertical wall. Turn on the low beam light, sit on the vehicle and check that the light beam projected to the wall is a little below the horizontal straight line of the headlight (about 9/10 of the total height).
  • Page 87 V100 E5 Maintenance • First remove the fuel tank. • Disconnect the connector (1) from the SAS valve. • Disconnect the connector (2) from the coolant temperature sensor on the left cylinder. • Once the connectors are disconnec- ted, release the wiring harness from its fitting on the canister.
  • Page 88 V100 E5 Maintenance • Remove the two screws fixing the can- ister to the frame. • Lift the canister to allow easy access to the SAS valve lines. • Open the clamps and remove the two pipes (3) on the right side of the SAS valve.
  • Page 89 V100 E5 Maintenance • Open the clamp and remove the breather pipe (6) from the canister. • Open the clamp and remove the pipe (7) from the left side of the SAS valve. • Remove the canister from the vehicle. •...
  • Page 90 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 91 V100 E5 Electrical system Alternator belt removal • First remove the fuel tank and the can- ister. • Remove the three fixing screws shown in the figure. • Remove the cover of the belt from the vehicle. • Remove the three fixing screws shown in the figure.
  • Page 92 V100 E5 Electrical system • Loosen the lock nut of the set screw. • Tighten the adjuster screw until it stops with the lock nut. • Remove the fixing screw of the adjust- ment bracket. • Unscrew almost completely the left fix- ing screw of the alternator, but DO NOT remove it.
  • Page 93 V100 E5 Electrical system • Press downwards the alternator so as to release the belt tension. • Remove the belt from the alternator pulley then remove it from the vehicle. Alternator belt installation • Install the belt on the engine pulley, then fit it on the alternator pulley.
  • Page 94 V100 E5 Electrical system • Screw in the fixing screw of the adjust- ing bracket, without tightening it. • Unscrew the adjusting screw to tem- porarily tension the belt. • Follow the belt tensioning procedure described below, not including parts related to component removal.
  • Page 95 V100 E5 Electrical system • Remove the three fixing screws shown in the figure. • Remove the right head support brack- • Using a digital frequency meter, meas- ure the belt tensioning frequency by vibrating it with your finger. Characteristic Alternator belt frequency 180 Hz •...
  • Page 96 V100 E5 Electrical system • Loosen the lock nut of the set screw. • Act on the adjuster screw, screwing it in to decrease the tensioning frequen- cy or unscrewing it to increase it. • Tighten the fixing screws (1) and (2) of the alternator to the specified torque.
  • Page 97 V100 E5 Electrical system • If the tension is correct, tighten the lock nut of the adjuster screw. • Otherwise, repeat the operations for the belt tensioning. • When the correct belt tension frequen- cy is reached, install the RH head sup- port bracket.
  • Page 98 V100 E5 Electrical system • Tighten the three fixing screws of the alternator belt cover. • Refit the canister and the fuel tank on the vehicle. Components arrangement ELE SYS - 98...
  • Page 99 V100 E5 Electrical system KEY: 1. ECU 2. Starter relay and main fuses; 3. Secondary fuses; 4. Fuel pump; 5. Fuel level sensor; 6. Right-hand aerodynamic flap actuator; 7. Adjustable top fairing actuator; 8. Coolant temperature sensor; 9. Front right turn indicator; 10.Front ABS sensor;...
  • Page 100 V100 E5 Electrical system 22.ABS Modulator; 23.Battery; 24.OBD5 port; 25.Rear light cluster; 26.Rear left turn indicator; 27.TPMS ECU; 28.GMP ECU; 29.Stand sensor; 30.Engine oil pressure sensor; 31.Left lambda probe; 32.Left pipette/coil; 33.Front left turn indicator; 34.Voltage regulator; 35.Front light cluster; 36.Left-hand aerofoil flap actuator;...
  • Page 101 V100 E5 Electrical system the connector (i.e., all terminals aligned at the same depth) and terminal integrity (i.e., that termi- 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 102 V100 E5 Electrical system CAUTION 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 disabling system that is activated automatically when the ignition key is removed.
  • Page 103 V100 E5 Electrical system If there is an immobilizer failure at ignition, the in- strument cluster requests you to enter a user code. If the code is entered correctly, the instrument cluster signals the failure by displaying the word SERVICE and the red general warning light turns Once the code has been correctly entered, the er- ror will be displayed on the screen, and you can still start the motorcycle.
  • Page 104 V100 E5 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 105 V100 E5 Electrical system • Occurs, when the transponder is working, but it is not within the recognised ones. Identification • General alarm warning continuously on (red) and indication "ALARM IMMO B0003" on the display Troubleshooting • Store the new key Error code B0004 (ALARM IMMO B0004) Error cause •...
  • Page 106 V100 E5 Electrical system Troubleshooting • Replace the instrument cluster Error code B0007 (ALARM 1 KEY STORED) Error cause • Occurs when the number of stored keys is less than two Identification • General alarm warning continuously on (red) and indication "ALARM 1 KEY STORED" on the display Troubleshooting •...
  • Page 107 V100 E5 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 dy- namic presentation screen, a message will appear with a countdown of 20 seconds to insert the second key to be programmed.
  • Page 108 V100 E5 Electrical system • Enable the command "SERVICE RE- SET". Infotainment INFOTAINMENT Key: 1. GMP ECU 2. OBD ECU 3. Ignition switch 4. Battery 5. Fuse ELE SYS - 108...
  • Page 109 V100 E5 Electrical system INSTRUMENT CLUSTER Key: 1. TFT instrument cluster 2. Ignition switch 3. Battery 4. Main fuse 5. Fuse ELE SYS - 109...
  • Page 110 V100 E5 Electrical system HEATED HAND GRIPS - Only for V100 Mandello S Key: 1. Instrument cluster 2. Right hand grip 3. Left hand grip 4. air temperature sensor 5. Immobilizer antenna Battery recharge circuit Key: (1) Generator. (2) Secondary fuse. •...
  • Page 111 V100 E5 Electrical system • Ignition switch set to ON, • Battery voltage below 14.8 Volt, • If voltage of at least 2 Volts is applied to the Sense connection. CAUTION Do not leave the vehicle with the engine off and the ignition key to "ON".
  • Page 112 V100 E5 Electrical system • Position the ammeter clamp (1) on the cable of the fuse (3). • With the ignition switch in the ON po- sition, but with the engine stopped, there will be a continuous current draw of 3.372A. NOTE Perform the measurements shown below with the lights off.
  • Page 113 V100 E5 Electrical system Start-up system check Function Communicates to the control unit the consent to start the engine. Operation / Operating principle Pressing the start button closes the relative circuit, bringing the ECU PIN 65 to zero voltage (closure to ground).
  • Page 114 V100 E5 Electrical system 2. Starter button 3. Starter Motor 4. 11MP ECU 5. Starter relay 6. Battery 7. Fuse Lights list HEADLAMP Key: 1. Headlamp 2. Fog lights 3. Front left turn indicator 4. Front right turn indicator 5. Instrument cluster 6.
  • Page 115 V100 E5 Electrical system TAILLIGHT Key: 1. Taillight 2. Rear right turn indicator 3. Rear left turn indicator 4. Licence plate lamp 5. 11MP ECU 6. Instrument cluster 7. Ignition switch 8. Battery 9. Fuse The 11MP control unit (5) controls the activation of the STOP light via pin 11. Fuses To check: •...
  • Page 116 V100 E5 Electrical system • If the fuse is damaged, replace it with one of the same current rating. NOTE IF THE SPARE FUSE IS USED, REPLACE WITH ONE OF THE SAME TYPE IN THE CORRE- SPONDING FITTING. MAIN FUSES MSS V100 Specification Desc./Quantity 40A fuse...
  • Page 117 V100 E5 Electrical system Control unit ENGINE TONE WHEEL PROGRAMMING PRO- CEDURE • Using the PADS diagnostic tool, per- form the "Reset wheel tooth values"; • Bring the engine to a temperature above 80°; Then proceed as described: • In neutral position, with the side stand extended/open and with the vehicle absolutely immobile, quickly bring the engine above 7000 RPM (it is not nec-...
  • Page 118 V100 E5 Electrical system MEANS IT HAS TO BE REPEATED. IN THIS CASE, REPEAT THE PROCEDURE WITH THE SIDE STAND CLOSED AND VEHICLE IN NEUTRAL ALWAYS PAYING EXTREME AT- TENTION. FOR MORE SAFETY, POSSIBLY BLOCK THE VEHICLE AGAINST A WALL. CAUTION PROGRAMMING OF THE TONE WHEEL TAKES PLACE DURING THE RELEASE PHASE OF THE THROTTLE...
  • Page 119 V100 E5 Electrical system Code Description / Symptoms D0860C Invalid suspension mode sensor signal D0860D Invalid front compression block HMI signal D0860E Invalid front rebound block HMI signal D0860F Invalid rear compression block HMI signal D08610 Invalid rear rebound block HMI signal D08611 Invalid steering damper block HMI signal D08612...
  • Page 120 V100 E5 Electrical system Removal • Remove the driver's seat and battery beforehand. • Lift the slide (1) and disconnect the connector (2). • Lift the slide (3) and disconnect the connector (4). • Remove the ECU (5) by pulling it up- wards.
  • Page 121 V100 E5 Electrical system • on the vehicle: under the driver's seat, between the tank and the battery. Pin out:See CONNECTORS paragraph (screen page/example values with key ON) • Drawing number / - (identified inserted by the manufacturer) • HW number/ - (indicates the Hardware number) •...
  • Page 122 V100 E5 Electrical system RECOVERY STRATEGIES Various recovery strategies, characterised by a progressively increasing level of impact on vehicle driving, are provided to ensure maximum driving safety while minimising inconvenience for the customer in the event of a breakdown. Depending on the impact the failure will have on the safe running/integrity of the engine, the indication on the instrument cluster may be more or less obvious: Level 1: error recognised, but not of safety significance and not noticeable to the driver =>...
  • Page 123 V100 E5 Electrical system • Segnale potenziometro posizione manopola (traccia B) / Handgrip position potentiometer signal (trace B) • Apertura manopola acceleratore in percentuale / Accelerator handgrip opening in percent- • Tensione farfalla destra potenziometro 1 / 1 potentiometer right throttle voltage •...
  • Page 124 V100 E5 Electrical system • Circonferenza ruota posteriore / Rear wheel circumference • Rapporto finale trasmissione / Transmission final ratio • Correzione adattativa carburante cilindro sinistro / LH cylinder fuel adaptive correction • Contatore errori blocchetto chiave / Ignition block key error counter •...
  • Page 125 V100 E5 Electrical system • Apprendimento ruota fonica / Phonic wheel learning • Immobilizer sbloccato tramite codice / Immobilizer unlocked by code • Codice o segnale immobilizer antenna ricevuto / Antenna immobilizer code or signal re- ceived • Codice Immobilizer / Immobilizer code •...
  • Page 126 V100 E5 Electrical system • Abilitazione sistema TPMS / TPMS system enabling • Disabilitazione sistema TPMS / TPMS system disabling • Abilitazione sistema RADAR BLIS / RADAR BLIS system enabling • Disabilitazione sistema RADAR BLIS / RADAR BLIS system disabling DIAGNOSTIC TOOL - ERRORS: 11MP ECU ERRORS...
  • Page 127 V100 E5 Electrical system Code Description / Symptoms P0230 Fuel Pump Relay Control - Open Circuit P0300 Random/multiple cylinder error 1000 detected P0300 Random/multiple cylinder error 200 detected P0301 Right cylinder error 1000 detected P0301 Right cylinder error 200 detected P0302 Left cylinder error 1000 detected P0302...
  • Page 128 V100 E5 Electrical system Code Description / Symptoms P1404 Right throttle valve supply voltage self-learning - below the minimum limit P1405 Right throttle valve spring test (re-closure) spring test self-learning - re-closure spring test failed P1406 Left throttle valve Limp Home self-learning - LH test failed P1407 Left throttle valve (opening) spring test self-learning - opening spring test failed P1408...
  • Page 129 V100 E5 Electrical system Code Description / Symptoms P2173 Left cylinder manifold pressure too low error - signal not plausible P2175 Right cylinder manifold pressure too low error - signal not plausible P2227 Barometric pressure sensor - generic hardware fault P2227 Barometric pressure sensor - Plausibility at key on U0001...
  • Page 130 V100 E5 Electrical system Code Description / Symptoms C1DF5 Hardware inside error C1DF7 Voltage too high C1E11 CAN BUS error C1E59 Vehicle variant coding error C1E5A ABS switch error C1F13 IMU - Invalid or not plausible data error C1F14 IMU - Incorrect Voltage C1F15 IMU - Signal error, before ABS initialisation C1F18...
  • Page 131 V100 E5 Electrical system CAV MODULE CONTROL UNIT Electrical specifications • Actuator motors electrical resistance: 14 Ohm Position • ECU: on the left side of the vehicle un- der the side panelling, attached to the left side radiator panelling. • Connector: on the control unit.
  • Page 132 V100 E5 Electrical system ABS CONTROL UNIT Position • ECU: Fastened to the ABS modulator, under the air filter box and expansion tank. • Connector: on the control unit. ABS CONTROL UNIT Key: 1. ABS control unit 2. Rear ABS sensor 3.
  • Page 133 V100 E5 Electrical system Battery Function Provides electrical power to vehicle. Level in electrical circuit diagram: Charging the battery Position: • on the vehicle: under the rider saddle • connector: on the battery Electrical specifications:12 V / 18 Ah Pin out: 1.
  • Page 134 V100 E5 Electrical system Phonic wheel sensor PICK UP Function Provide the ECU with the crankshaft position and thus the engine timing, to adjust the ignition timing of the cylinders. Position: Pick up: Inside the timing housing, above the tone wheel.
  • Page 135 V100 E5 Electrical system (1) PURGE valve 1. Track power supply 1 2. Track 1 ground 3. Track 1 signal 4. Track power supply 2 5. Track 2 ground 6. Track 2 signal (2) 11MP ECU 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...
  • Page 136 V100 E5 Electrical system 1. Earth. 2. Intake air temperature signal. 3. Pressure sensor power supply. 4. Intake air pressure signal. (3) 11MP ECU Engine temperature sensor ENGINE OIL TEMPERATURE SENSOR Function It is used to inform the ECU regarding the engine oil temperature in order to optimize parameter management.
  • Page 137 V100 E5 Electrical system COOLANT TEMPERATURE SENSOR Function It is used to inform the ECU regarding the coolant temperature in order to optimize engine parameter management. Operation / Operating principle NTC type sensor (resistance sensor, inversely variable with temperature). Level in electrical circuit diagram:Temperature sensors Position: •...
  • Page 138 V100 E5 Electrical system It requires no external power but must reach a high operating temperature (closed loop) to operate properly: that is why there is a heating circuit in- side. Closed loop lambda control varies the mixture to continuously oscillate the state of the probe be- tween rich and lean and it is used throughout the range of the emission cycle.
  • Page 139 V100 E5 Electrical system 2. Sensor signal - (grey wire) 3. Heater ground connection (white cable) 4. Heater power supply (white cable) Fuse 15A (3) Fuse 30A (4) Injection relay (5) Battery (6) Injector INJECTORS Function Ensure the correct amount of fuel in the correct stage of the cycle.
  • Page 140 V100 E5 Electrical system Key: (1) RH injector: 1. Power supply +Vbatt 2. Activation from the control unit (2) LH injector: 1. Power supply +Vbatt 2. Activation from the control unit (3) 11MP ECU (4) Injection relay (5) Fuse (6) Battery Fuel pump Function Fuel pump: keeps pressure of the injectors supply...
  • Page 141 V100 E5 Electrical system Pin Out : 1. Not connected. 2. Earth. 3. Not connected. 4. Not connected. 5. Fuel pump relay power supply. Electrical circuit 1. Fuel pump. 2. 11MP ECU. 3. Fuel pump relay. 4. Injection relay. 5. Fuse. 6.
  • Page 142 V100 E5 Electrical system Electrical specifications: • Primary circuit resistance (pin 1 and 3): 650 ± 50 mohm • Secondary circuit resistance: 4 ± 0.5 Kohm Right coil pin out (1): 1. Power supply (+Vbatt) 2. Secondary circuit ground connection 3.
  • Page 143 V100 E5 Electrical system Throttle and handgrip sensor control (Demand) Position: • on the vehicle: under the air filter box • connector: on the throttle body RH cylinder throttle body Pin Out (1): 1. TPS 1 signal 2. TPS power supply 3.
  • Page 144 V100 E5 Electrical system In fact, the throttle valve correction starts operating when the lambda probe check starts. From the throttle correction value it is possible to determine whether the engine has ventilation problems (in the case of corrections during closure) or fouled bodies (in the case of corrections during). A negative correction - 0.6 °...
  • Page 145 V100 E5 Electrical system Neutral sensor GEAR SENSOR Function It is used to indicate to the ECU which gear is en- gaged. Operation / Operating principle Each gear engaged has a sensor position, which in turn will have a higher output voltage as the gear engaged increases.
  • Page 146 V100 E5 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, meaning with the circuit closed to ground, there is consent to start the vehicle.
  • Page 147 V100 E5 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 unit does not enable vehicle start-up or shuts off the engine if it is rotating Level in electrical circuit diagram:...
  • Page 148 V100 E5 Electrical system Electric fan circuit RADIATOR ELECTRIC FAN Key: 1. Electric fan 2. Electric fan relay 3. 11MP ECU 4. Injection relay 5. Fuse 6. Battery SAS valve actuator Function Quickly warms up the catalytic converter and keeps the combustion rich in some critical condi- tions .
  • Page 149 V100 E5 Electrical system • (1) The PURGE valve: under the bat- tery compartment, fixed to the canister support. • (2) Secondary air valve: Under the bat- tery compartment, on the right side of the vehicle. • Connectors: On the relative valves. Electrical specifications: PURGE valve electrical resistance at 20 °C: 24 ±...
  • Page 150 V100 E5 Electrical system Electrical circuit diagram - Level in electrical circuit diagram: • Electronic gearbox. Position: • On the gearbox lever gear. Electrical specifications: • Switch normally open. Key: (1) Quick shift 1. Power supply (+ 5 Volt) 2. Signal 3.
  • Page 151 V100 E5 Electrical system Electrical circuit: Key: 1. Inertia platform 2. Fuse 3. Ignition switch 4. Main fuse 5. Battery Suspension valves SUSPENSION CONTROL UNIT - only V100 Mandello S Key: 1. Suspension control unit 2. Rear shock absorber compression adjuster 3.
  • Page 152 V100 E5 Electrical system Can line Function Allows the communication between: • 11MP ECU; • TFT instrument cluster; • Front headlamp; • Suspension control unit; • CAV control unit. 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 153 V100 E5 Electrical system • Communication speed: messages travel at a speed of 250 kbps (data arrive at nodes every 20 ms, i.e. 50 times/second). CAN PROTOCOL (CONT. NETWORK AREA) The communication protocol is CSMA/CD (Carrier Sense Multiple Access w/ Collision Detection). In order to transmit, every nod must first check that the BUS (the connection among all devices) is free before attempting to send a message with BUS (Carrier Sense).
  • Page 154 V100 E5 Electrical system ELE SYS - 154...
  • Page 155 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 156 V100 E5 Engine from vehicle Vehicle preparation CAUTION TO CARRY OUT THE MAINTENANCE OPERATIONS AND IF THERE IS THE NEED TO RAISE THE VEHICLE, USE A PANTOGRAPH LIFT PLACED IN CORRESPONDENCE WITH THE OIL SUMP.IN ORDER TO AVOID DAMAGES, PLACE A PROTECTION BETWEEN THE OIL SUMP AND THE LIFT. To remove the engine from the vehicle, first perform the following operations: •...
  • Page 157 V100 E5 Engine from vehicle • Remove the connector (1) from its re- tainer on the internal side of the rear wheel housing and disconnect it. CAUTION MAKE SURE TO RECONNECT THE CONNECTOR (1) DUR- ING REFITTING, OTHERWISE IT WILL NOT BE POSSIBLE TO START THE ENGINE.
  • Page 158 V100 E5 Engine from vehicle • Unscrew the fixing nut (4) and remove the PURGE valve from its support. • Unscrew the fixing nut (5) of the engine ground cable. • Unscrew the fixing nut of the rear brake hose clamp. •...
  • Page 159 V100 E5 Engine from vehicle • Cut the plastic clamp shown in the fig- ure, on both sides of the vehicle. • Remove the 4 cable gland clips and re- move the side covers of the radiator. • Repeat on the opposite side. •...
  • Page 160 V100 E5 Engine from vehicle • Remove the head support bracket (9) from the frame. Repeat the removal operations for the bracket on the opposite side. • Remove the screws fixing the engine to the front frame. During refitting, tighten the fixing screws to the prescribed torque.
  • Page 161 V100 E5 Engine from vehicle • Remove the engine from the frame by pulling downward. Take extra care not to damage any components during re- moval. ENG VE - 161...
  • Page 162 INDEX OF TOPICS NGINE...
  • Page 163 V100 E5 Engine TO CONSULT THE CHAPTER ABOUT THE ENGINE AND ITS COMPONENTS PLEASE REFER TO THE APPROPRIATE MANUAL: "MSS Engine Guzzi V100" ENG - 163...
  • Page 164 INDEX OF TOPICS P SUPP OWER SUPPLY...
  • Page 165 V100 E5 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 Nuts fixing the fuel level probe to the 1 Nm (0.74 lb ft) fuel tank...
  • Page 166 V100 E5 Power supply • Remove the safety tab (1) from the fuel pipe. • Press the external ring (2) and remove the pipe (3) from the fuel pump. • Unscrew and remove the ring nut from the tank. • Extract the pump from the tank and re- trieve the gasket (4).
  • Page 167 V100 E5 Power supply CAUTION During refitting, the pump connector must be turned to- ward the rear side of the tank. Injection Removing the throttle body To access the throttle bodies, the battery must be disconnected and the following components re- moved: •...
  • Page 168 V100 E5 Power supply Unscrew the right intake duct fixing screws. Remove the right intake duct. Unscrew the left intake duct fixing screws. Remove the left intake duct. P SUPP - 168...
  • Page 169 V100 E5 Power supply Disconnect the two throttle body ECU connectors by pulling the relative tab. Disconnect the two throttle body ECU connectors. P SUPP - 169...
  • Page 170 V100 E5 Power supply Perform the following operations for both throttle bodies. Loosen the throttle body retaining calmp from the engine sleeve. Lift up the throttle body and remove the retaining calmp. Disconnect the air temperature/pressure sensor connector. Remove the vacuum hose. P SUPP - 170...
  • Page 171 V100 E5 Power supply Remove the throttle body. Installing the throttle body HROTTLE BODIES Pos. Description Type Quantity Torque Note Injector mounting fixing screw 11 ÷ 13 Nm (8.11 ÷ 9.59 lbf ft) Air temperature/pressure sensor fas- 11 ÷ 13 Nm (8.11 ÷ 9.59 tening screw lbf ft) Throttle body fastening screw...
  • Page 172 V100 E5 Power supply Perform the following operations for both throttle bodies. Position the throttle body near the engine sleeve. Insert the vacuum tube. Connect the air temperature/pressure sensor con- nector. Place the throttle body retaining calmp on the en- gine sleeve.
  • Page 173 V100 E5 Power supply Screw the throttle body retaining calmp to the en- gine sleeve. Connect the two throttle body ECU connectors by locking them with the appropriate tab. Position the intake ducts on the throttle bodies. Tighten intake duct fixing screws. P SUPP - 173...
  • Page 174 V100 E5 Power supply Screw in the fixing screw of the pipe metal retain- ing calmp to the fuel tank. Proceed to reassemble the following components: • Air filter box • fuel tank • tank cover • left and right side fairing •...
  • Page 175 INDEX OF TOPICS SUSP USPENSIONS...
  • Page 176 V100 E5 Suspensions Front Handlebar ANDLEBAR ONTROLS Pos. Description Type Quantity Torque Notes Screws fastening the lower U-bolts to 50 Nm (36.88 lbf ft) Loctite 243 the upper steering yoke Screws fastening the lower U-bolt 25 Nm (18.44 lbf ft) clamp to the handlebar Screws fastening the anti-vibration 10 Nm (7.38 lbf ft)
  • Page 177 V100 E5 Suspensions Removing • First remove the rear-view mirrors. • Remove the anti-vibration weight from the handlebar, on both sides. During refitting, tighten the anti-vibration weight to the prescribed torque. Locking torques (N*m) Screw fastening the anti-vibration weight 10 Nm (7.38 lbf ft) •...
  • Page 178 V100 E5 Suspensions • Loosen the screw fastening the throttle control. • Remove the throttle control from the handlebar and place it on the vehicle, taking care not to damage the body- work. WARNING It is not possible to replace only the throttle control grip as it is integrated with the throttle control.
  • Page 179 V100 E5 Suspensions • Support the front brake pump and un- screw the two fixing screws (1) of the fixing U-bolt (2). • Remove the front brake pump from the handlebar and place it on the tank, tak- ing care not to tension the pipe or dam- age the bodywork.
  • Page 180 V100 E5 Suspensions • Remove the lower fixing screw (4) of the left knob. • Remove the left hand handle from the handlebar and place it on the vehicle, taking care not to damage the body- work. DURING REFITTING, MAKE SURE TO INSERT THE FIXING SCREWS OF THE HANDLE IN THE RELEVANT THREADED HOLES OF THE HANDLEBAR.
  • Page 181 V100 E5 Suspensions • Support the clutch pump and unscrew the two screws (7) of the fixing U-bolt (8). • Remove the clutch pump from the han- dlebar and place it on the tank, taking care not to tension the pipe or damage the bodywork.
  • Page 182 V100 E5 Suspensions Front fork RONT FORK Pos. Description Type Quantity Torque Notes Screws fastening the calliper mount- 10 ± 1.5 Nm (7.38 ± 1.10 ing bracket to the wheel axle lb ft) SUSP - 182...
  • Page 183 V100 E5 Suspensions TEERING Pos. Description Type Quantity Torque Notes Ring nut fastening the bottom yoke/ First tightening tor- steering pin assembly to the head- que 60 Nm (44.25 stock lbf ft) - Second tight- ening torque 30 Nm +/- 5 Nm (22.13 +/- 3.69 lbf ft) Counter-lock ring fastening the bot- Manual...
  • Page 184 V100 E5 Suspensions TO AVOID DAMAGING THE CONNECTOR, PRESS THE TAB (2) ON THE INDICATED POINT AND THEN CAREFUL- LY REMOVE THE CONNECTOR. PAY SPECIFIC ATTENTION WHEN DISCONNECTING THE CONNECTORS, TO AVOID DAMAGING THEM, WHICH WOULD COMPROMISE THE OPERATION OF THE VEHI- CLE.
  • Page 185 V100 E5 Suspensions • Loosen the cable gland clamp from the fork stanchion. • Loosen the screw (2) of the upper steering plate. During refitting, tighten the screw to the prescribed torque. Locking torques (N*m) Upper steering plate screw 25 ± 2.5 Nm (18.44 ± 1.84 lbf ft) •...
  • Page 186 V100 E5 Suspensions INSTALLATION • Follow the removal procedure in re- verse order; be careful to tighten the retainers to the specified tightening tor- ques. NOTE DURING REFITTING, INSERT THE FORK STANCHIONS IN THE STEERING PLATES SO AS TO OBTAIN 12 mm BE- TWEEN THE UPPER STEERING PLATE AND THE UPPER EDGE OF THE FORK STANCHION (MEASURED UNDER THE SLEEVE CAP).
  • Page 187 V100 E5 Suspensions • Loosen the cap using a wrench in order to release the upper nut on the spring retaining ring. • Unscrew the upper adjustment cap us- ing the special Ohlins tool. Specific tooling 01761-04 Ohlins fork cap ring nut •...
  • Page 188 V100 E5 Suspensions • Remove the pre-loading spring. • Empty the fork oil into a special con- tainer, taking care not to let the pre- loading tube come out. Disassembling the fork V100 Mandello NOTE THE FOLLOWING OPERATIONS REFER TO THE KAYABA FORKS WITH MECHANICAL AD- JUSTMENTS.
  • Page 189 V100 E5 Suspensions • Using the special tool (2), fastened to the pre-loading pipe (3), compress the spring and, with the assistance of a second operator, insert the separator plate (4) under the cap retaining nut (5). Specific tooling 020888Y Pre-load tube clamp AP8140148 Plunger-spacer separator plate •...
  • Page 190 V100 E5 Suspensions • 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 191 V100 E5 Suspensions • Remove the seeger ring (10) from in- side the sleeve. • Pull the stem repeatedly towards your- self in order to remove it from the sleeve. • Secure the stem in a vice and remove the plunger fastening screw (11), tak- ing care not to lose the copper washer (12).
  • Page 192 V100 E5 Suspensions • 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). THE FOLLOWING OPERATIONS APPLY WHEN REMOVING THE RIGHT HAND STEM •...
  • Page 193 V100 E5 Suspensions • 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. DO NOT DISPOSE OF OIL IN THE ENVIRONMENT.
  • Page 194 V100 E5 Suspensions • Remove the seeger ring (5) from inside the sleeve. • Pull the stem repeatedly towards your- self in order to remove it from the sleeve. • Observing the indicated sequence, ex- tract and remove the slider bushing (6), the guide bushing (7), the ring (8), the oil seal (9), the seeger ring (5) and the dust guard (4).
  • Page 195 V100 E5 Suspensions • Remove the wheel holder shaft (1) and the sleeve (2). • Clamp the sleeve in a vice and, by lev- ering it alternately at various points, remove the anti-dust seal (3) from the sleeve (2). • Remove the retaining ring (4).
  • Page 196 V100 E5 Suspensions PROCEED WITH EXTREME CAUTION IN ORDER TO PREVENT FOREIGN BODIES FROM EN- TERING THE SLEEVE OR THE WHEEL HOLDER SHAFT. DO NOT REUSE THE OIL THAT WAS DRAINED EARLIER Checking the components V100 Mandello NOTE THE FOLLOWING OPERATIONS REFER TO THE KAYABA FORKS WITH MECHANICAL AD- JUSTMENTS.
  • Page 197 V100 E5 Suspensions stanchion Check that the sliding surface is not scratched or scored. Any scoring can be removed by sanding with damp sandpaper (grain 1). 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 .
  • Page 198 V100 E5 Suspensions • Insert the complete plunger (7). • Secure the stem in a vice and, after in- serting the screw (8) used to fasten the plunger, complete with the copper washer (9), apply the pre-defined tight- ening torque. •...
  • Page 199 V100 E5 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 200 V100 E5 Suspensions • Insert the pre-load tube (11), making sure that it is aligned correctly. The narrower part must be inserted into the spring. • Insert the upper plate (12) on the pre- load pipe • After positioning the device (13) on the pre-load pipe (11) and the plunger sup- port shaft (14), with the assistance of a second operator, raise the plunger so...
  • Page 201 V100 E5 Suspensions • 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. CAUTION CHECK THE O-RING PRESENT ON THE FILLING CAP AND REPLACE IF DAMAGED.
  • Page 202 V100 E5 Suspensions 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 203 V100 E5 Suspensions • 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" section. •...
  • Page 204 V100 E5 Suspensions • 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. • Ensure that the cap cannot rotate, and then tighten the nut. •...
  • Page 205 V100 E5 Suspensions • Fix the sleeve in a vice, taking care not to damage the sleeve. • Insert the stanchion (1) into the sleeve (2). • Position the two halves of the special tool on the shaft (1) behind shaft seal (5), together with the respective buffer.
  • Page 206 V100 E5 Suspensions Specific tooling AP8140189 Tool for fitting oil seal for 43 mm (1.69 in) diameter hole AP8140146 Weight Filling oil V100 Mandello NOTE THE FOLLOWING OPERATIONS REFER TO THE KAYABA FORKS WITH MECHANICAL AD- JUSTMENTS. RIGHT-HAND STANCHION FILLING. •...
  • Page 207 V100 E5 Suspensions LEFT-HAND STANCHION FILLING. • Place the fork stanchion in a vice and lock it in a vertical position. • Fill the stanchion with the specified oil quantity. WARNING OPERATE THE PLUNGER MULTIPLE TIMES UNTIL AIR BUBBLES MAY BE SEEN ON THE SURFACE OF THE OIL. THE FORK MUST BE PERFECTLY UPRIGHT IN ORDER TO MEASURE THE CORRECT OIL LEVEL.
  • Page 208 V100 E5 Suspensions THE SLEEVE MUST BE PERFECTLY UPRIGHT IN ORDER TO MEASURE THE CORRECT OIL LEVEL. THE OIL LEVEL MUST BE THE SAME IN BOTH STANCHIONS. Specific tooling AP8140149 Guard for assembly operations Oil level: 160 mm (6.30 in) (from the edge of the sleeve, without spring or pre-fill pipe).
  • Page 209 V100 E5 Suspensions • Position the ring nut on the preload spring and keeping it compressed, screw the lock nut on the pumping el- ement • Tighten the nut as much as possible. • Insert the cover and tighten until it stops.
  • Page 210 V100 E5 Suspensions • Place the handlebar on the tank. To avoid damage to the bodywork, place a protective cloth on the tank before placing the handlebar. • Loosen the screw (3) of the steering plate, on both sides. During refitting, tighten the screws to the prescri- bed torque.
  • Page 211 V100 E5 Suspensions Removing • To remove the lower steering plate, in- stall a workshop stand to the rear wheel and place a pantograph jack un- der the engine to lift the front wheel off the ground. Check the stability of the vehicle.
  • Page 212 V100 E5 Suspensions • Using the specific tool, unscrew the counter-lock ring (4). Specific tooling 020966Y Steering adjustment socket Remove the counter-lock ring (4) and the rubber spacer (5). • Using the specific tool, unscrew and remove the ring nut (6) of the steering headstock.
  • Page 213 V100 E5 Suspensions • Remove the shim washer (8) of the up- per bearing. • Remove the internal ring (9) of the up- per bearing. • Remove the balls of the upper bearing (10). Remove the lower steering plate from the vehicle. SUSP - 213...
  • Page 214 V100 E5 Suspensions • Remove the balls of the lower bearing (11) from the steering plate. Steering bearing TEERING Pos. Description Type Quantity Torque Notes Ring nut fastening the bottom yoke/ First tightening tor- steering pin assembly to the head- que 60 Nm (44.25 stock lbf ft) - Second tight-...
  • Page 215 V100 E5 Suspensions Adjusting play To adjust the steering play, follow the procedure described below: • Place the vehicle so that the front wheel is off the ground. • Carry out a handlebar rotation test, using a dynamometer at the hand grip external end. •...
  • Page 216 V100 E5 Suspensions • Unscrew the lower ring nut (4) using the special tool. Repeat the steering assembly tightening proce- dure in the correct manner as described: • Pre-tighten the ring nut (4) to 60 Nm (44.25 lbf ft). • Turn the handlebar to the left and right as far as it will go to seat the bearings.
  • Page 217 V100 E5 Suspensions • Remove the lower steering plate. • Using a generic bearing extractor, re- move the outside seat of the upper steering bearing. • Using a generic bearing extractor, re- move the outside seat of the lower steering bearing. •...
  • Page 218 V100 E5 Suspensions • Using the specific tool, completely in- sert the external seat of the upper bear- ing. Lubricate the inserted seat with grease for bearings. Specific tooling 020376Y Adaptor handle 020360Y 52 x 55 mm adaptor • Using the specific tool, completely in- sert the external seat of the lower bear- ing.
  • Page 219 V100 E5 Suspensions • Lubricate the internal seat (5) of the upper steering bearing with bearing grease. • Support the lower steering plate and insert the internal seat (5) inside the steering headstock. • Support the lower steering plate and insert the dust seal ring (6) on the steering headstock.
  • Page 220 V100 E5 Suspensions • Using the specific tool, pre-tighten the ring nut (8) to the torque of 60 Nm (44.25 lbf ft). • Turn the handlebar to the right and left until the end of the stroke, to allow the bearings to settle.
  • Page 221 V100 E5 Suspensions • Insert the safety plate (11) on the ring nuts of the steering headstock. • Refit the previously removed compo- nents. Rear Shock absorbers REAR SHOCK ABSORBER Pos. Description Type Quantity Torque Notes Upper shock absorber fixing screw 50 ±...
  • Page 222 V100 E5 Suspensions Removing Properly support the vehicle by means of a pan- tograph. Unscrew the fixing screws of the preload tank to the support bracket. Remove the preload tank. Position the preload tank so that it is not in the way of subsequent operations;...
  • Page 223 V100 E5 Suspensions While holding the rear nut (1), unscrew the screw (2). Remove the screw (2). Retrieve the nut (1). While holding the rear nut (3), unscrew the screw (4). SUSP - 223...
  • Page 224 V100 E5 Suspensions Remove the screw (4). Retrieve the nut (3). Remove the damper complete with the preload tank. FOR "MANDELLO S" VERSION Before removing the damper with the preload tank as described above, the electrical connectors of the wiring harness from the electronic suspension ECU must be disconnected.
  • Page 225 V100 E5 Suspensions Proceed as follows: • remove the passenger and driver's seat; • remove the battery cover; • disconnect and remove the battery; • disconnect and remove the engine ECU; • remove the engine ECU bracket; Remove the right side panel and remove the inner side fairing underneath.
  • Page 226 V100 E5 Suspensions Remove the rear brake oil tank by unscrewing the fixing screw. Remove the fixing rubber calmp from the rear brake hose. Remove the fixing metal calmp from the rear brake hose. Unscrew and remove the saddle screw so that it can be detached from the chassis.
  • Page 227 V100 E5 Suspensions Cut the fixing calmp from the electrical wiring har- nesses. Remove the second ECU suspension wire har- ness connector from the saddle. Disconnect the second connector. Installing Position the shock absorber complete with preload tank in its seat. SUSP - 227...
  • Page 228 V100 E5 Suspensions Insert the rear nut (3). Holding the rear nut (3), tighten the screw (4) to the prescribed torque. Insert the rear nut (1). Holding the rear nut (1), tighten the screw (2) to the prescribed torque. SUSP - 228...
  • Page 229 V100 E5 Suspensions Position the preload tank on the support bracket and tighten the fixing screws to the prescribed tor- que. NOTE FOR THE "MANDELLO S" VERSION, PROCEED WITH THE INSTALLATION OF THE ELECTRICAL WIRING BY PER- FORMING THE OPERATIONS IN REVERSE ORDER FROM THE REMOVAL.
  • Page 230 INDEX OF TOPICS CHAS HASSIS...
  • Page 231 V100 E5 Chassis FOR MAINTENANCE/REPAIR WORK AND WHERE THERE IS A NEED TO LIFT THE VEHICLE WHEELS OFF THE GROUND, INSTALL A WORKSHOP STAND AT THE REAR WHEEL AND PLACE A PANTOGRAPH JACK UNDER THE OIL SUMP. PLACE A GUARD BETWEEN THE JACK AND THE OIL SUMP TO PREVENT DAMAGE TO THE OIL SUMP.
  • Page 232 V100 E5 Chassis Completely remove the tyre from the rim. Remove the screw (1) that fastens the TPMS sen- sor to the valve. Remove the retaining nut (2) and slide off the valve (3) from inside the rim. Fit the new valve kit for TPMS (3) - code 2D000689 for tubeless wheels.
  • Page 233 V100 E5 Chassis Insert and tighten the valve retaining nut (2) to the prescribed torque. Locking torques (N*m) Valve retaining nut 4.7 ± 0.25 Nm (3.47 ± 0.18 lb ft) Install and tighten to the prescribed torque the screw (1) that fastens the TPMS sensor to the valve.
  • Page 234 V100 E5 Chassis • select the "SELF-DIAGNOSIS" function • Select the "ADJUSTMENTS" tab • select "vehicle configuration" and press "OK" • select "front wheel TPMS learning" and press "OK" CHAS - 234...
  • Page 235 V100 E5 Chassis • When required by P.A.D.S., deflate the front tyre, until the learning is complete. WARNING THE DEFLATION / LEARNING OPERATION MUST BE PERFORMED WITHIN A MAXIMUM 90 SECONDS. CAUTION TO BE ABLE TO PERFORM THE CALIBRATION, THE SENSOR MUST DETECT A DECREASE IN TYRE INFLATION PRESSURE.
  • Page 236 V100 E5 Chassis Front wheel RONT WHEEL Pos. Description Type Quantity Torque Notes Nut fastening the front wheel axle M25x1.5 80 Nm (59.01 lbf ft) Brake disc fixing screw 6 + 6 30 Nm (22.13 lbf ft) Loctite 243 ABS sensor fixing screw 6 Nm (4.46 lbf ft) CHAS - 236...
  • Page 237 V100 E5 Chassis Removal REMOVAL To remove the front wheel, install a workshop stand to the rear wheel and place a pantograph jack under the engine to lift the front wheel off the ground. Check the stability of the vehicle. To avoid damaging the vehicle, place a protection between the jack and the sump oil.
  • Page 238 V100 E5 Chassis • Remove the fixing screw and remove the ABS sensor (4) from its housing on the right hand calliper mounting brack- • Unscrew the nut of the wheel axle (5) and recover the relative washer (6). • Loosen the screws of the right foot.
  • Page 239 V100 E5 Chassis • Slide off the wheel axle from the front suspension. • Remove the front wheel from the vehi- cle. • Remove the spacer (7) on the right side of the wheel. REMOVAL OF EXTERNAL WHEEL COMPO- NENTS After removing the front wheel, operating from the right side: •...
  • Page 240 V100 E5 Chassis • Remove the right-hand brake disc (10). • Working on the opposite side, unscrew the six fixing screws (11) and remove the left-hand brake disc (12). REMOVAL OF INTERNAL WHEEL COMPO- NENTS • Remove the dust guard (13). Remove the bearing using a generic extractor, proceeding as follows: •...
  • Page 241 V100 E5 Chassis REPEAT THE OPERATION DESCRIBED ABOVE, TO RE- MOVE THE BEARING ON THE OPPOSITE SIDE OF THE WHEEL. • Once the first bearing has been removed, retrieve the inner spacer from the wheel hub before removing the second bearing. Checking FRONT WHEEL BEARINGS Check the bearings installed on the wheel.
  • Page 242 V100 E5 Chassis WHEEL AXLE • Use a dial gauge to measure the ec- centricity of the wheel axle. Replace the wheel axle if the eccentricity meas- ured exceeds the specified limit. Characteristic Maximum eccentricity: 0.25 mm (0.0098 in) • Use a dial gauge to check that the ra- dial (A) and axial (B) eccentricity of the wheel do not exceed the specified lim-...
  • Page 243 V100 E5 Chassis • Insert the inner spacer the wheel hub, and repeat the insertion of the bearing on the opposite side. • Insert the dust seal (13) and bring it flush with the wheel hub. • Repeat the operation for the dust seal on the opposite side.
  • Page 244 V100 E5 Chassis FRONT WHEEL INSTALLATION • Install the front wheel on the vehicle and insert the wheel axle into the fork feet. • Tighten the screws of the right foot to the prescribed torque. Locking torques (N*m) Calliper mounting bracket screw 10 Nm (7.38 lbf •...
  • Page 245 V100 E5 Chassis • Reinsert the ABS sensor (4) in its seat and tighten the fixing screw. • Fit the brake calliper (2) on the brake disc and tighten the fixing screws (1) to the prescribed torque. • Repeat for the brake calliper on the op- posite side.
  • Page 246 V100 E5 Chassis Rear wheel REAR WHEEL Pos. Description Type Quantity Torque Notes Rear wheel nut M60x2 260 ± 39 Nm (191.75 ± 28.76 lb ft) Rear brake disc fixing screw 30 ± 4.5 Nm (22.12 ± Screws with pre-ap- 3.32 lb ft) plied threadlocker Rimozione...
  • Page 247 V100 E5 Chassis • Open the safety circlip (1). • Remove the safety circlip (1) from the hole on the wheel hub and remove it from the vehicle. • Unscrew the nut (2) from the hub. During refitting, tighten the nut (2) to the prescribed torque.
  • Page 248 V100 E5 Chassis Checking • Check the wheel for damage to the mating surfaces with the wheel hub and fixing nut. Also check that there are no signs of damage and/or for cracks along the spokes and the duct of the rim.
  • Page 249 V100 E5 Chassis Removing • First remove the bevel gear. • Cut the plastic clamp (1) from the dust guard cap. • Holding the nut (2), unscrew the lower fixing screw (3) of the rear shock ab- sorber. During refitting, tighten the fixing screw to the pre- scribed torque.
  • Page 250 V100 E5 Chassis • Loosen the screw (4) of the swingarm pivot. During refitting, tighten the screw of the swingarm pivot to the prescribed torque. Locking torques (N*m) Swingarm pivot screw 28 ± 4 Nm (20.65 ± 2.95 lbf ft) •...
  • Page 251 V100 E5 Chassis Removing • First remove the rear wheel, the bevel gear and the swingarm. • Using a suitable tool, apply force on the gearbox output shaft (1) in order to re- lease the cardan shaft (2) from the gearbox output shaft spline.
  • Page 252 V100 E5 Chassis Bevel gears EVEL GEAR Pos. Description Type Quantity Torque Notes Bevel gear fixing screws 45 ± 6.5 Nm (33.19 ± 4.79 lb ft) CHAS - 252...
  • Page 253 V100 E5 Chassis REAR WHEEL TRANSMISSION - COMPONENTS Pos. Description Type Quantity Torque Notes Fixing screw for rear gearbox cover M8x1 25 Nm (18.43 lb ft) Screws with pre-ap- plied threadlocker Pinion fixing ring nut 140 Nm (103.25 lb ft) With Loctite 243 Flanged nut fixing pinion M20x1...
  • Page 254 V100 E5 Chassis • Remove the upper fastener screw (3). • Remove the two lower fixing screws (4). • Remove the bevel gear from the rear swingarm. Removal CAUTION CARRY OUT OIL DRAINING AND PROCEED WITH THE REMOVAL OF THE BREATHER BEFORE DISASSEMBLING THE GEARBOX.
  • Page 255 V100 E5 Chassis Place the specific tool in a vice and secure it prop- erly. Specific tooling 021066Y Gearbox mounting Place the complete gearbox on the specific tool. CHAS - 255...
  • Page 256 V100 E5 Chassis Use the screws to secure the complete gearbox to the swingarm and lock the gearbox to the specific tool. Pay attention because the lower screws are equip- ped with a locking nut. Insert the supplied flange with the specific tool on the sprocket hub, bringing it into contact with the case cover.
  • Page 257 V100 E5 Chassis Screw the specific tool arm onto the flange. Heat the sleeve seat using an air heater. Unscrew the pinion fixing cap. CHAS - 257...
  • Page 258 V100 E5 Chassis Remove the shim underneath the cap. Reheat the sleeve seat using an air heater. Unscrew the pinion fixing flanged nut. Remove the flanged nut. CHAS - 258...
  • Page 259 V100 E5 Chassis Extract the sleeve. Heat the seat of the ring nut using an air heater. To remove the ring nut, use the specific tool by inserting the relevant bolts into the holes in the ring nut. Specific tooling 021067Y Pinion side fixing ring nut socket Make sure to bring the specific tool to a stop on the ring nut.
  • Page 260 V100 E5 Chassis Using the specific tool, unscrew the ring nut. Remove the ring nut. Separate the ring nut from the specific tool. Remove the o-ring from the pinion. CHAS - 260...
  • Page 261 V100 E5 Chassis Remove the oil seal from the ring nut. Remove the sealing ring from the ring nut by tap- ping with a suitable punch. Unscrew the arm of the specific tool to release the flange. Remove the supplied flange with the specific tool from the sprocket hub.
  • Page 262 V100 E5 Chassis Unscrew the fixing screws of the gearbox cover. Using a rubber hammer, slightly separate the cov- er from the case so that the shims can be removed. Remove the first shim. Remove the second shim. CHAS - 262...
  • Page 263 V100 E5 Chassis Remove the complete sprocket hub with the cover from the gearbox. Remove the o-ring from the sprocket hub. Position the complete sprocket hub with gearbox cover in a suitable press, using suitable supports. WARNING BEFORE USING THE PRESS, ENSURE THAT THE SUP- PORTS USED REST EVENLY ON THE SURFACE OF THE COVER IN ORDER TO PREVENT DAMAGE TO COMPO- NENTS.
  • Page 264 V100 E5 Chassis Operate the press in order to disassemble the case cover from the sprocket hub. WARNING NOTE BEFORE USING THE PRESS TO DISASSEMBLE THE SPROCKET HUB FROM THE COVER, IT IS RECOMMEN- DED THAT THE INVOLVED AREA BE HEATED WITH AN AIR HEATER IN ORDER TO FACILITATE DECOUPLING.
  • Page 265 V100 E5 Chassis Checking • After assembly of the box, it is necessary to check the play between the pinion and the crown. Clamp in a vice and install a dial gauge by means of a suitable support. The dial gauge tester must be placed the outer end of a tooth positioned at 90°.
  • Page 266 V100 E5 Chassis Insert the gearbox cover on the sprocket hub. Position the complete sprocket hub with gearbox cover in a suitable press, using suitable supports. WARNING BEFORE USING THE PRESS, ENSURE THAT THE SUP- PORTS USED REST EVENLY ON THE SURFACE OF THE COVER IN ORDER TO PREVENT DAMAGE TO COMPO- NENTS.
  • Page 267 V100 E5 Chassis Place the first shim on the mating surface with the cover, aligning it with the profile of the case itself. Place the second shim with the inscription on the upper side. Insert the complete sprocket hub with the cover into the gearbox.
  • Page 268 V100 E5 Chassis Insert all fixing screws on the case cover. Tighten the screws to the prescribed torque, ob- serving a crosswise sequence. Place the specific tool in a vice and secure it prop- erly. Specific tooling 021066Y Gearbox mounting Place the complete gearbox on the specific tool.
  • Page 269 V100 E5 Chassis Insert a new sealing ring inside the ring nut, mak- ing sure to bring it up to its stop. WHEN REASSEMBLING, ALWAYS REPLACE THE SEAL- ING RING WITH A NEW ONE. Insert a new oil seal in the ring nut. Insert the supplied flange with the specific tool on the sprocket hub, bringing it into contact with the case cover.
  • Page 270 V100 E5 Chassis Clean the ring nut perfectly before assembly. Use the specific tool by inserting the relevant bolts in the holes of the ring nut. Specific tooling 021067Y Pinion side fixing ring nut socket Using the tool, insert the ring nut on the pinion. Using the specific tool, tighten the ring nut to the prescribed torque.
  • Page 271 V100 E5 Chassis Insert the sleeve. Insert the flanged nut. Tighten the pinion fixing flange nut to the prescri- bed torque. Insert the shim with the chamfer facing the cap. CHAS - 271...
  • Page 272 V100 E5 Chassis Make sure the shim is correctly positioned in its seat. Insert the pinion fixing cap. Tighten the pinion fixing cap to the prescribed tor- que. Unscrew the arm of the specific tool to release the flange. CHAS - 272...
  • Page 273 V100 E5 Chassis Remove the supplied flange with the specific tool from the sprocket hub. Installing • Install the bevel gear on the swingarm, taking care to properly insert the car- dan shaft in its splines. • Insert the two lower fixing screws (4) and tighten them to the prescribed tor- que.
  • Page 274 V100 E5 Chassis • Insert the ABS sensor (2) in the corre- sponding seat on the bevel gear. • Tighten the fixing screw (1) of the ABS sensor (2). • Top up the oil following the instructions in the "Maintenance / Transmission oil / Replace- ment"...
  • Page 275 V100 E5 Chassis TAND Pos. Description Type Quantity Torque Notes Nut for fastening the stand to the 25 ± 3.5 Nm (18.44 ± stand plate 2.58 lb ft) Stand switch lock pin 10 ± 2 Nm (7.38 ± 1.48 Pre-applied Loct. lb ft) Pin fastening the spring to the stand 25 ±...
  • Page 276 V100 E5 Chassis • Remove the two fastening screws (2). During refitting, tighten the fixing screws to the prescribed torque. Locking torques (N*m) Side stand fixing screw 25 ± 3.5 Nm (14.75 ± 2.58 lb • Remove the stand and the correspond- ing support from the vehicle.
  • Page 277 V100 E5 Chassis SILENCER Pos. Description Type Quantity Torque Notes Screw fastening outer silencer sup- 25 ± 5 Nm (18.43 ± 3.68 port bracket lb ft) Upper silencer fixing screw to the 10 ± 2 Nm (7.37 ± 1.47 footrest lb ft) Lower silencer fixing screw to the 25 ±...
  • Page 278 V100 E5 Chassis • Remove the screw and its fixing lock nut used to fasten the terminal to the frame. During refitting, tighten the fixing screw to the pre- scribed torque. Locking torques (N*m) Support bracket terminal fastener 25 Nm (18.44 lbf •...
  • Page 279 V100 E5 Chassis Unscrew the lower calmp located inside the heat shield. Remove the heat shield from the exhaust manifold by loosening the metal calmps. When reassembling, loosen the calmps and place the heat shield on the manifold. Tighten the upper and lower clamps and the fixing screw to the prescribed torque.
  • Page 280 V100 E5 Chassis • Remove the two nuts (2) of the exhaust flange, on both heads. During refitting, tighten the nuts to the prescribed torque. Locking torques (N*m) Exhaust flange fixing nut 25 ± 4 Nm (14.75 ± 2.95 lbf •...
  • Page 281 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
  • Page 282 V100 E5 Braking system RONT BRAKE MASTER CYLINDER Pos. Description Type Quantity Torque Notes Screws fixing brake pump clamp to 10 ± 1.5 Nm (7.38 ± 1.11 the handlebar lb ft) RONT BRAKE CALLIPER Pos. Description Type Quantity Torque Notes Screws fastening front brake calliper M10x1.25 50 ±...
  • Page 283 V100 E5 Braking system EAR BRAKE MASTER CYLINDER Pos. Description Type Quantity Torque Notes Rear brake rod lock nut 6 ± 1 Nm (4.23 ± 0.74 lb Rear brake pump fastening screws 10 ± 1.5 Nm (7.38 ± 1.11 lb ft) Brake oil tank fixing screw 6 ±...
  • Page 284 V100 E5 Braking system ABS CONTROL UNIT Key: 1. ABS control unit 2. Rear ABS sensor 3. Front ABS sensor 4. Ignition switch 5. Battery 6. Fuse Modulator REMOVAL • Drain the brake system completely. • First remove the fuel tank, the air filter housing, the radiator and the expan- sion tank.
  • Page 285 V100 E5 Braking system • Remove the joints and collect the seal- ing washers from each pipe. DURING REFITTING, USE NEW SEALING WASHERS. • Remove the jig (1) for pipe positioning from the ABS modulator. • Remove the lower fixing nut (2). •...
  • Page 286 V100 E5 Braking system • Remove the lateral fastener screw (4). • Remove the ABS modulator from its seat. • Press the safety tab and push the con- nector locking lever (5) forward. • Disconnect the modulator connector. • Remove the modulator from the vehi- cle.
  • Page 287 V100 E5 Braking system • Once the brake calliper pipes are connected, remove the protective caps from the inlet ports from the brake pumps and connect the respective pipes to the ABS modulator • Remove the plugs of the brake pump tanks and fill them with new brake fluid CAUTION PERFORM THE STANDARD BRAKING SYSTEM BLEEDING PROCEDURE, AS DESCRIBED AT THE END OF THE CHAPTER.
  • Page 288 V100 E5 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. (0.47 in)).
  • Page 289 V100 E5 Braking system Characteristic Distance between tone wheel and front sensor 0.5 - 1.50 mm (0.020 - 0.059 in) TONE WHEEL CLEANING • It is important to check regularly that the front tone wheel is clean. If this is not the case, carefully remove any dirt using a cloth or a brush.
  • Page 290 V100 E5 Braking system • Remove the two rear brake calliper fix- ing screws (1). During refitting, tighten the fixing screws to the prescribed torque. NOTE TO REMOVE THE BRAKE CALLIPER, IS NOT NECESSARY TO REMOVE THE REAR WHEEL. Locking torques (N*m) Brake calliper fixing screw 50 ±...
  • Page 291 V100 E5 Braking system • Insert the screw and the associated seal washers in the brake pipe fitting, in the order shown in the figure. DURING REFITTING, USE NEW SEALING WASHERS. • Install the brake pipe on calliper and tighten the special screw of the fitting. •...
  • Page 292 V100 E5 Braking system • Using a rubber pipe, connect a con- tainer to the bleed screw (1) and loosen it to allow the fluid to flow. • Press thoroughly the brake lever and lock it in position, in order to prevent fluid leakages from the brake pipe.
  • Page 293 V100 E5 Braking system • Insert the special screw (2) in the brake pipe couplings using new sealing washers (3). • Install the screw / joints assembly on the brake calliper and tighten the spe- cial screw (2). • Remove the clamp from the front brake lever. •...
  • Page 294 V100 E5 Braking system Removal • First remove the rear wheel. • Remove the two screws (1) fastening the rear brake calliper. During refitting, tighten the fixing screws to the prescribed torque. Locking torques (N*m) Rear brake calliper fixing screw 50 ±...
  • Page 295 V100 E5 Braking system THE BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE SPECI- FICATIONS OF THE SYSTEM. • The following operations must be car- ried out with brake disc fitted on the wheel. • Check the disc for wear by measuring the minimum thickness with a micro- meter in different points.
  • Page 296 V100 E5 Braking system • The following operations must be car- ried out with the brake discs fitted on the wheel; they refer to a single disc, but are valid for both. • Check the disc for wear by measuring the minimum thickness with a micro- meter in different points.
  • Page 297 V100 E5 Braking system Front brake pads Removal THIS VEHICLE IS FITTED WITH A DOUBLE DISC FRONT BRAKING SYSTEM (RIGHT AND LEFT SIDE). ALWAYS REPLACE ALL THE PADS FROM BOTH FRONT BRAKE CALLIPERS. REPLACING THE PADS OF ONLY ONE FRONT CALLIPER MAY JEOPARDISE THE VEHICLE STABILITY AND SAFETY, POSING SERIOUS DANGER FOR PEOPLE, OBJECTS AND THE VE- HICLE ITSELF.
  • Page 298 V100 E5 Braking system • Remove the external pad (4) from the calliper. • Remove the internal pad (5) from the calliper. DO NOT OPERATE THE BRAKE LEVER ONCE THE BRAKE PADS HAVE BEEN REMOVED, AS THIS MAY FORCE THE PISTONS OUT FROM THEIR SEATS AND ALLOW BRAKE FLUID TO ESCAPE.
  • Page 299 V100 E5 Braking system • Install the external pad (4) in the cal- liper, making sure that the support arm is facing the upper part. • Install the spring (3) in the calliper. • Insert the fixing pin (2) in the calliper, ensuring that it passes over the spring and that it is correctly inserted pad bushes.
  • Page 300 V100 E5 Braking system Removal • Press the brake calliper, from the out- side, to retract the piston. • Remove the cotter pins (1) from the pin. Remove the pin (2) from the brake calliper. • Remove the external brake pad (3) from the calliper.
  • Page 301 V100 E5 Braking system • Remove the internal brake pad (4) from the calliper. Installing • Insert the internal pad (4) in the calliper and lock it in position by inserting the pin (2) in the relative eyelet of the pad. CAUTION ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED INSIDE THE CALLIPER.
  • Page 302 V100 E5 Braking system MAKE SURE THAT THE FRONT PART OF THE PADS IS INSERTED CORRECTLY IN ITS SEAT ON THE BRAKE CALLIPER SUPPORT. Bleeding the braking system PREPARATION OF THE VEHICLE • Place the vehicle on a flat surface and in vertical position.
  • Page 303 V100 E5 Braking system NOTE THE FOLLOWING OPERATIONS REFER TO ONE FRONT BRAKE CALLIPER ONLY, BUT ARE VALID FOR BOTH. THE VEHICLE MUST BE ON LEVEL GROUND TO BE BLED. WHILE PURGING THE HYDRAULIC SYSTEM, FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID.
  • Page 304 V100 E5 Braking system • Insert an 8 mm spanner on the bleed- ing valve and attach a rubber hose (4) to the valve connection. • Connect the other end of the rubber hose to a suitably sized container. • FULLY press and release the front brake lever quickly for several times.
  • Page 305 V100 E5 Braking system • Top up the tank with brake fluid to the correct level. • Replace the protective rubber, the tank cap and tighten the two fixing screws. BLEEDING SYSTEM WITH DIAGNOSTIC INSTRUMENT If the brake lever still feels "spongy" after completing all checks, it is necessary to bleed the brakes using this type of procedure.
  • Page 306 V100 E5 Braking system Rear brake circuit • Unscrew the cap (1) of the rear brake fluid tank. • Remove the protective rubber (2). • Refill the tank with brake fluid. CAUTION DURING BLEEDING OPERATIONS, CONSTANTLY TOP UP THE TANK SO THAT IT NEVER RUNS EMPTY. OTHERWISE AIR WILL ENTER THE CIRCUIT AND THE BLEEDING OP- ERATION WILL HAVE TO BE STARTED ALL OVER AGAIN.
  • Page 307 V100 E5 Braking system • Insert an 8 mm spanner on the bleed- ing valve and attach a rubber hose (3) to the valve connection. • Connect the other end of the rubber hose to a suitably sized container. • FULLY press and release the rear brake pedal quickly for several times.
  • Page 308 V100 E5 Braking system • Top up the tank with brake fluid to the correct level. • Replace the protective rubber and screw the tank cap back on. BLEEDING SYSTEM WITH DIAGNOSTIC INSTRUMENT If the brake lever still feels "spongy" after completing all checks, it is necessary to bleed the brakes using this type of procedure.
  • Page 309 V100 E5 Braking system Front brake circuit NOTE THE OPERATIONS CONCERNING THE FRONT BRAKE CIRCUIT REFER TO ONLY ONE BRAKE CALLIPER, BUT ARE VALID AND MUST BE CARRIED OUT ON BOTH. • Unscrew the two screws (1) and re- move the cap (2). •...
  • Page 310 V100 E5 Braking system • Remove the rubber cap from the bleed valve. • Insert an 8 mm spanner on the bleed valve and attach the rubber hose (3), from the pneumatic pump, to the valve connection. • Operate the pneumatic pump for bleeding and open the bleeding valve of the brake calliper.
  • Page 311 V100 E5 Braking system • Check the brake lever stroke and that the pressure does not feel "spongy". Otherwise, it means that there is air in the circuit and it must be bled. • Once the operations are finished, re- place the rubber cap on the bleeding valve.
  • Page 312 V100 E5 Braking system • Remove the protective rubber (2). • Refill the tank with brake fluid. • Remove the rubber cap from the bleed valve. • Insert an 8 mm spanner on the bleed valve and attach the rubber hose (3), from the pneumatic pump, to the valve connection.
  • Page 313 V100 E5 Braking system • Operate the pneumatic pump for bleeding and open the bleeding valve of the brake calliper. • Repeat the steps until the fluid coming out of the brake calliper is light-col- oured; then close the bleed valve and stop the pneumatic pump.
  • Page 314 V100 E5 Braking system • Top up the tank with brake fluid to the correct level. • Replace the protective rubber and screw the tank cap back on. Front brake pump Removal • Place a container under the pump to collect the brake fluid.
  • Page 315 V100 E5 Braking system • Remove the U-bolt and front brake master cylinder from the vehicle. Rear brake pump Rimozione • Place a container under the pump to collect the brake fluid. • Remove the union screw (1) and re- trieve the sealing washers (2).
  • Page 316 V100 E5 Braking system • Remove the rear brake pump from the vehicle. REAR BRAKE FLUID RESERVOIR REMOVAL • Place a container under the pump to collect the brake fluid. • Remove the metal clamp (1) and re- move the rubber pipe (2) from the tank (3).
  • Page 317 V100 E5 Braking system • Unscrew the front brake pump connec- tor. • Remove the connector from the front brake pump and collect the sealing washers. DURING REFITTING, USE NEW SEALING WASHERS. • Unscrew the connector from the mod- ulator. •...
  • Page 318 V100 E5 Braking system • Remove the brake pipe from the vehi- cle as shown in the figure. MODULATOR PIPE / RIGHT FRONT BRAKE CALLIPER • Remove the four pipe grommets from the front brake pipe. • Unscrew the connector from the mod- ulator.
  • Page 319 V100 E5 Braking system • Unscrew the connector from the brake calliper. • Remove the connector from the front brake calliper and collect the three sealing washers. NOTE DURING REASSEMBLY, THE PIPE FROM THE MODULA- TOR (2) GOES OVER THE CALLIPER COMMUNICATING PIPE (3).
  • Page 320 V100 E5 Braking system • Unscrew the connector from the brake calliper. • Remove the connector from the front brake calliper and collect the three sealing washers. NOTE DURING REASSEMBLY, THE PIPE FROM THE MODULA- TOR (2) GOES OVER THE CALLIPER COMMUNICATING PIPE (3).
  • Page 321 V100 E5 Braking system • Remove from the vehicle the front brake calliper connection pipe, as shown in the figure REAR BRAKE PUMP PIPE - MODULATOR • Unscrew the connector of the rear brake pump. • Remove the connector of the rear brake pump and retrieve the two seal- ing washers.
  • Page 322 V100 E5 Braking system • Remove the connector from the mod- ulator and collect the sealing washers. DURING REFITTING, USE NEW SEALING WASHERS. • Release the rigid pipe from the lower clip (1) used to fasten it to the frame. •...
  • Page 323 V100 E5 Braking system MODULATOR PIPE - REAR BRAKE CALLIPER • Unscrew the modulator connector. • Remove the connector from the mod- ulator and collect the sealing washers. DURING REFITTING, USE NEW SEALING WASHERS. • Unscrew the rear brake calliper con- nector.
  • Page 324 V100 E5 Braking system • Remove the screw fixing the pipe grommet to the clutch housing. • Release the rigid pipe from the lower clip (1) used to fasten it to the frame. • Release the rigid pipe from the upper clip (2) used to fasten it to the frame.
  • Page 325 V100 E5 Braking system • Remove the brake pipe from the swing- arm, passing it between the shock ab- sorber and the mudguard, as shown in the figure. • Remove the brake pipe from the vehi- cle, pulling it upward, as shown in the figure.
  • Page 326 INDEX OF TOPICS CLU SYS LUTCH SYSTEM...
  • Page 327 V100 E5 Clutch system Removing the clutch master cylinder CLUTCH PIPE REMOVAL • Drain the fluid completely from the clutch control circuit. • Unscrew the coupling of the clutch master cylinder. • Remove the connector from the clutch master cylinder and collect the sealing washers.
  • Page 328 V100 E5 Clutch system • Remove the two pipe grommets from the left beam of the frame. • Pass the clutch pipe between the en- gine and the frame, as illustrated in the figure. • Remove the clutch pipe from the vehi- cle, pulling it upward, as shown in the figure.
  • Page 329 V100 E5 Clutch system Removing the clutch slave cylinder • Remove the union screw (1) and re- trieve the sealing washers (2). DURING REFITTING, USE NEW SEALING WASHERS. • Remove the two fixing screws (3) of the rear shock absorber preload adjuster. During refitting, tighten the fixing screws to the prescribed torque.
  • Page 330 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
  • Page 331 V100 E5 Cooling system Coolant replacement PERFORM THE INDICATED OPERATIONS WHEN THE ENGINE IS COLD. • Place the vehicle upright and prepare a container of adequate size under the oil sump. • Remove the filler plug of the expansion tank. •...
  • Page 332 V100 E5 Cooling system • Remove the pipe from the "indicator light" fitting on the water pump. • Remove the bleed screw and allow the coolant to drain completely from the water pump. Cooling circuit filling • Insert the bleed screw on the water pump using a NEW sealing washer and tighten it to the specified torque.
  • Page 333 V100 E5 Cooling system • Insert the drain screw of the radiator with a NEW sealing washer and tighten it to the specified torque. • Refill the radiator with the Anti-freeze liquid specified. NOTE Refill the radiator up to the lower edge of the filler plug. •...
  • Page 334 V100 E5 Cooling system • Fill the expansion tank with the speci- fied anti-freeze liquid up to the MAX mark. • Fit the expansion tank cap. • Start the engine and let it idle until the radiator fan starts. NOTE THE COOLING SYSTEM OF V100 IS SELF-BLEEDING.
  • Page 335 V100 E5 Cooling system • Disconnect the connectors and re- move the horn from the vehicle. • Remove the cap from the radiator. • Place a container under the radiator, remove the drain plug and completely drain the coolant from the radiator. •...
  • Page 336 V100 E5 Cooling system • Release the fairing from the relative re- tainer to the radiator, sliding it down- ward. • Disconnect the turn indicator connec- tor and remove the side fairing from the vehicle. • Repeat the operations for the fairing of the side opposite side.
  • Page 337 V100 E5 Cooling system • Remove the second lower screw fas- tening the radiator. (The first fastens the horn and has been removed previ- ously.) • Open the metal clamp (3) and remove the pipe that connects the radiator to the expansion tank.
  • Page 338 V100 E5 Cooling system • Disconnect the electrical fan connector (6) and pull the wiring harness out of the vehicle. • Loosen the metal clamp (7) and re- move the right pipe from the radiator. • Remove the radiator from the vehicle, sliding it downward and by extracting it laterally.
  • Page 339 V100 E5 Cooling system • Open the metal clamp and remove the pipe that connects the radiator to the expansion tank. DURING REFITTING, USE A NEW CLAMP. • Remove the fixing screw. • Lift the rear part of the expansion tank to remove it from its housing on the ABS modulator.
  • Page 340 V100 E5 Cooling system • Remove the expansion tank from the vehicle. Thermostatic valve Removing • Preventively remove: 1. The top fairing; 2. The side fairings; 3. The fuel tank; 4. The air filter housing; 5. The throttle bodies. • Open the filler cap and remove the ra- diator bleed screw (shown in the fig- ure), so that the coolant is completely...
  • Page 341 V100 E5 Cooling system • Remove the front fixing screw (2) and retrieve the corresponding cup wash- • Remove the two rear fixing screws (3) and retrieve the relative cup washers. • Remove the metal clamps (4) from the sleeves connecting the valve to the ra- diator.
  • Page 342 V100 E5 Cooling system • Remove the thermostatic valve as- sembly from the vehicle. • Remove the plate (6) from the thermo- static valve • Remove the O-ring (7). REPLACE THE O RING UPON EACH REMOVAL. • Remove the three fixing screws (8). COOL SYS - 342...
  • Page 343 V100 E5 Cooling system • Remove the fitting (9). • Remove the thermostatic valve (10) from the valve body. Installing • Follow the removal operations but in reverse order; be careful to carry out the tightening of the fixing screws in two different stages: WARNING BEFORE PLACING THE THERMOSTATIC VALVE ASSEM-...
  • Page 344 V100 E5 Cooling system • Install: 1. The throttle bodies; 2. The air filter housing; 3. The fuel tank; 4. The side fairings; 5. The top fairing. • Fill the cooling circuit following the pro- cedure shown in the chapter: "Coolant change".
  • Page 345 INDEX OF TOPICS BODYW ODYWORK...
  • Page 346 V100 E5 Bodywork Seat • Rest the vehicle on its stand. • Insert the key in the saddle lock located on the left-hand side fairing. • Turn the key clockwise to release the passenger saddle from the lock. • Lift the front part of the passenger sad- dle and bring it toward the rear of the vehicle to remove it.
  • Page 347 V100 E5 Bodywork • Insert the rear fastener of the passen- ger saddle in its support on the vehicle. • Keeping the saddle in position, press downward the front part to engage the lock. Instrument panel REMOVAL • First remove the front light cluster. •...
  • Page 348 V100 E5 Bodywork • Release the connector from the instru- ment support. • Disconnect the connector of the wiring harness of the adjustable windshield, then remove the frame of the wind- shield itself from the vehicle. • Disconnect the connector of the instru- ment panel wiring harness.
  • Page 349 V100 E5 Bodywork • Remove the instrument panel from the three rubber bushings and remove it from the vehicle. Headlight assy. FRONTAL SPOILER REMOVAL • First remove the top fairing and the side fairings. • Remove the left-hand fixing screw. •...
  • Page 350 V100 E5 Bodywork • Disconnect the wiring harness connec- tor and remove the spoiler from the vehicle. FRONT HEADLAMP REMOVAL • Remove the front spoiler. • Remove the two upper fixing screws. • Remove the two lower fixing screws. • Remove the headlamp from its hous- ing.
  • Page 351 V100 E5 Bodywork • Disconnect the connector from the headlamp. • Remove the headlamp from the vehi- cle. Horn REMOVAL • Remove the fixing screw of the horn/ lower radiator support. • Disconnect the two connectors and re- move the horn from the vehicle. BODYW - 351...
  • Page 352 V100 E5 Bodywork Turn indicators REMOVING FRONT TURN INDICATORS • First remove the side fairings. • Unscrew the two upper fixing screws of the radiator side fairing. • Release the fairing from the relative re- tainer to the radiator, sliding it down- ward.
  • Page 353 V100 E5 Bodywork • Release the retaining claw (3) from the inside of the radiator side fairing. • Remove the turn indicator (4) from the radiator side fairing. • Repeat the removal operations for the turn indicator on the opposite side. REAR TURN INDICATORS REMOVAL •...
  • Page 354 V100 E5 Bodywork • Disconnect the connectors of the turn indicators. NOTE THE RED AND BLUE WIRING HARNESS OF THE VEHICLE IS CONNECTED TO THE RIGHT TURN INDICATOR. • Remove the fixing screw (3), holding the nut from the rear. •...
  • Page 355 V100 E5 Bodywork • Remove the windshield from the vehi- cle. • Remove the five fixing screws of the lower front fairing element. • Remove the front lower fairing from the vehicle, pulling it downward. • Unscrew the two fixing screws of the right internal cover of the top fairing.
  • Page 356 V100 E5 Bodywork • Remove the right internal cover from the vehicle. • Repeat the operation for the left cover. • Remove the four fixing screws of the upper front fairing. • Lifting with the hands the points indi- cated in the figure, release the front upper fairing (1) from the side fairings (2).
  • Page 357 V100 E5 Bodywork • Retrieve the top fairing side moulding, on both sides. Disassembling the lock REMOVAL • First remove the left fairing. • Remove the screw (1) and the washer (2) fastening the lock lever. • Lift the lever from the lock pawl lock and remove it.
  • Page 358 V100 E5 Bodywork • Remove the pawl extracting it from the external side from the fairing. • Remove the plate (3). • Remove the clip fixing the pawl. FITTING • Insert the pawl in the left side fairing, taking care to insert the guide (4) into its seat of the fairing.
  • Page 359 V100 E5 Bodywork • Install the plate (3), taking care to insert the centring holes in the relative guides on the fairing. • Install the fastening clips of the pawl. • Install the spring on the pawl, taking care to insert the lower pin in its seat on the pawl.
  • Page 360 V100 E5 Bodywork • Install the washer (2) and tighten the fixing screw (1). Taillight assy. REMOVAL • First remove the rear handle, the stor- age compartment and the panels of the tail fairing. • Remove the rear screw (1) on both sides.
  • Page 361 V100 E5 Bodywork • Remove the lower fixing screw (4) of the rear light cluster. • Remove the rear light cluster from its seat. Disconnect the connector (5) and remove the light cluster from the vehicle. License plate light REMOVAL •...
  • Page 362 V100 E5 Bodywork • Remove the cover (2) from the vehicle. • Disconnect the license plate light con- nector (3). • Remove the two fixing screws (4) and extract the license plate light (5) from the license plate support. Rider footrest plate RIGHT FOOTREST PLATE REMOVAL •...
  • Page 363 V100 E5 Bodywork • Remove the pump from the footrest plate and fix it to the vehicle. • Remove the upper fixing screw (2) and retrieve the washer (3). During refitting, tighten the fixing screw to the pre- scribed torque. Locking torques (N*m) Footrest plate fixing screw 25 ±...
  • Page 364 V100 E5 Bodywork • Remove the screw (7) fixing the stop sensor to the footrest plate. During refitting, tighten the fixing screw to the pre- scribed torque. • Remove the right footrest plate from the vehicle. REMOVING THE REAR BRAKE LEVER •...
  • Page 365 V100 E5 Bodywork • Release the return spring (3) of the lev- er from the right footrest bracket. • Remove the spring (3) from the rear brake lever. • Remove the screw / pin (4) fastening the rear brake lever. During refitting, tighten the pin to the prescribed torque.
  • Page 366 V100 E5 Bodywork • Remove the screw (1) and retrieve the washer (3). • Remove the fixing screw (4) and re- trieve the washer (5). During refitting, tighten the fixing screw to the pre- scribed torque. Locking torques (N*m) Footrest plate fixing screw 25 ±...
  • Page 367 V100 E5 Bodywork • Rotate the footrest to reach the trans- mission (9) of the gearbox lever and remove the safety clip (10). • Remove the transmission (9) from the gearbox lever and remove the left foot- rest plate (11) from the vehicle. REMOVING THE GEAR SHIFT LEVER •...
  • Page 368 V100 E5 Bodywork • Remove the gear lever from the foot- rest plate. • Retrieve the pin (1), the O. R. (4) and the washer (5). Passenger footrest plate LEFT FOOTREST PLATE REMOVAL • Remove the two fastening screws (1). During refitting, tighten the fixing screws to the prescribed torque.
  • Page 369 V100 E5 Bodywork • Remove the two fastening screws (3). During refitting, tighten the fixing screws to the prescribed torque. Locking torques (N*m) Footrest plate fixing screw 25 ± 3.5 Nm (14.75 ± 2.58 lb ft) • Remove the right footrest plate from the vehicle.
  • Page 370 V100 E5 Bodywork • Remove the pin (3) and remove the footrest from the footrest support plate. • Retrieve the return spring (4) from the footrest. REMOVING THE NON-SLIP RUBBER • Remove the two screws (1) • Remove the non-slip rubber (2) from the footrest.
  • Page 371 V100 E5 Bodywork • Remove the fastening plate (3) from the anti-slip rubber (2). NOTE The left rubbers are marked with "L" and the right with "R" and can be fitted both for the rider and for the passenger. Side body panels REMOVAL The operations described below refer to the left side fairing, but are valid for the right side fairing...
  • Page 372 V100 E5 Bodywork • Remove the cable from the operating lever, then remove the fairing from the vehicle. Glove-box REMOVAL • First remove the rear handle. • Remove the five fixing screws. NOTE To remove the storage compartment it not is necessary to remove the tail fairing panels.
  • Page 373 V100 E5 Bodywork Side fairings REMOVAL • First remove the top fairing. • Remove the four fixing screws and then remove the cover of the tank (1) from the vehicle. NOTE THE OPERATIONS DESCRIBED BELOW REFER TO THE REMOVAL OF ONLY ONE SIDE PANELLING, BUT ARE VALID FOR BOTH.
  • Page 374 V100 E5 Bodywork • Remove the lower fastening screw. • Remove the three rear fixing screws. • Release the front fasteners by pulling the side fairing outward. • Move the fairing toward the rear to re- lease it from the fuel tank. BODYW - 374...
  • Page 375 V100 E5 Bodywork • Disconnect the connector of the aero- dynamic guard's wiring harness, then remove the fairing from the vehicle. AERODYNAMIC FLAP REMOVAL Disconnect the battery and remove: • top fairing • front fairing cover; • right and left instrument cluster; •...
  • Page 376 V100 E5 Bodywork Please note that there are washers on the 2 flap fixing screws. Turn the fairing and remove the flap. If necessary, remove the mushroom-shaped grommets from the fairing. Place the complete inner cover with supports and actuator on a steady surface. BODYW - 376...
  • Page 377 V100 E5 Bodywork Unscrew the fixing screws of the first plate. Remove the first plate. Unscrew the fixing screws of the second plate. Remove the second plate. BODYW - 377...
  • Page 378 V100 E5 Bodywork Remove the fixing cir-clip of the actuator connect- ing rod. Remove the actuator connecting rod from the bracket. Remove the mount. Unscrew the fixing screws for the actuator assem- bly from the additional support. BODYW - 378...
  • Page 379 V100 E5 Bodywork Remove the actuator assembly. Unscrew the fixing screws for the actuator assem- bly from the actuator bracket. Remove the actuator assembly. FITTING For reassembly, carry out the operations descri- bed for removal in reverse order, paying particular attention to the mounting of the plates.
  • Page 380 V100 E5 Bodywork Once the flap has been inserted, before refitting the inner cover, grease the seat for the 2 washers properly. Place the 2 washers on their respective seats on the flap, then proceed to fixing the inner cover. Fairing mounting panels REMOVING THE RIGHT HAND UNDER-FAIR- •...
  • Page 381 V100 E5 Bodywork • Remove the expansion cap (3). • Remove the expansion cap (4). • Remove the fixing screw (5). • Move the under-fairing forward to re- move it from the tail fairing. BODYW - 381...
  • Page 382 V100 E5 Bodywork • Disconnect the connector (6). • Operating from the internal side, re- move the clip fastening the connector (6) to the under-fairing. • Cut the plastic clamp (7) as shown in the figure. • Remove the connector (8) from the un- der-fairing.
  • Page 383 V100 E5 Bodywork • Press the fixing clip (9) with the clamps and remove it from the under-fairing. • Remove the right under-fairing from the vehicle. REMOVING THE LEFT HAND UNDER-FAIRING • First remove the left side fairing. • Remove the fixing screw (1). •...
  • Page 384 V100 E5 Bodywork • Remove the expansion cap (3). • Remove the expansion cap (4). • Remove the fixing screw (5). • Move the under-fairing forward to re- move it from the tail fairing. BODYW - 384...
  • Page 385 V100 E5 Bodywork • Remove the connector (6) from its sup- port on the under-fairing. • Operating from the internal side, re- move the clip (7) fastening the connec- tor to the under-fairing. • Remove the left under-fairing from the vehicle.
  • Page 386 V100 E5 Bodywork • Remove the license plate holder (2) from the vehicle. Air box • First remove the fuel tank. • Loosen the two clamps (1) of the throt- tle body manifolds. • Open the clamp and disconnect the left breather pipe (2) from the filter box.
  • Page 387 V100 E5 Bodywork • Open the clamp and disconnect the right breather pipe (3) from the filter box. • Remove the right fixing screw of the fil- ter box. • Remove the filter box from the vehicle by extracting it upward. DURING REASSEMBLY, ENSURE THE CORRECT INSER- TION OF THE AIR FILTER HOUSING MANIFOLDS ON THE THROTTLE BODIES.
  • Page 388 V100 E5 Bodywork Fuel tank FUEL TANK COVER REMOVAL • First remove the rider saddle and the side fairings. • Open the tank plug. • Remove the three external fixing screws (1). • Remove the internal fixing screw (2). • Remove the tank cap from the tank it- self.
  • Page 389 V100 E5 Bodywork • Remove the two fixing screws on the right side of the tank. • Remove the two fixing screws on the left side of the tank. • Remove the tank cover from the vehi- cle, lifting it upward. FUEL TANK REMOVAL •...
  • Page 390 V100 E5 Bodywork • Remove the vent pipe (2), on both sides. • Remove the safety tab from the fuel pipe quick coupling. • Press the fuel coupling on the sides and simultaneously extract the pipe from the coupling. • Disconnect the connector of the fuel pump / fuel level sensor wiring har- ness.
  • Page 391 V100 E5 Bodywork • Remove the left-hand fixing screw. • Remove the right-hand fixing screw. • Remove the tank from the vehicle pull- ing it upward. FUEL LEVEL SENSOR NOTE The fuel level sensor can be removed even if the tank is mounted on the vehicle. The procedure is the same as that described below, just remove the tank cover.
  • Page 392 V100 E5 Bodywork • Remove the fixing nuts (1) of the flange (2). • Remove the flange (2) from the sensor (3). • Remove the sensor (3) from the tank and retrieve the gasket (4). Rear wheelhouse REMOVAL • Preventively remove: The battery, the control unit, the tail fairing, the storage compartment, the rear light cluster and the license plate support.
  • Page 393 V100 E5 Bodywork • Remove the internal fixing screw (1), which can be reached from inside the battery compartment. • Remove the wiring harnesses from the two cable glands shown in the figure. • Extract the secondary fuse boxes from the relative supports on the wheel arch.
  • Page 394 V100 E5 Bodywork • Remove the expansion cap (3). • Repeat on the opposite side. • Move the cover of the rear frame, in or- der to remove the right fixing screw (4) of the wheel arch. • Move the cover of the rear frame, in or- der to remove the left fixing screw (5) of the wheel arch.
  • Page 395 V100 E5 Bodywork • Remove the two rear screws (7). • Lower the wheel arch and place it on the rear wheel. • Disconnect the connectors (8) and (9). • Extract the starter relay (10) from its support on the wheel arch. •...
  • Page 396 V100 E5 Bodywork • Remove the fixing nut and remove the SAS valve (12) from the wheel arch. • Disconnect the connector (13). • Remove the rear wheelhouse from the vehicle. Front mudguard REMOVAL • Remove the hose guide (1) from the rear side of the mudguard.
  • Page 397 V100 E5 Bodywork • Remove the two RH fixing screws. • Remove the two LH fixing screws. • Remove the front mudguard (2) from the vehicle. Pannier mounting REMOVAL • First remove the tail fairing, the storage compartment, the rear light cluster and the license plate support.
  • Page 398 V100 E5 Bodywork • Remove the two screws (2) that join the left and right supports. • Remove the fixing screw (3). • Remove the fixing screw (4). • Remove the left support (5) from the vehicle. BODYW - 398...
  • Page 399 V100 E5 Bodywork • Remove the fixing screw (6). • Remove the fixing screw (7). • Remove the right support (8) from the vehicle. Rear grab rail REMOVAL • Remove the passenger saddle. • Remove the four fixing screws (1). BODYW - 399...
  • Page 400 V100 E5 Bodywork • Remove the rear handle (2) from the vehicle. Instrument cluster support REMOVAL • First remove the front light assembly and the instrument panel. • Remove the connectors (1) and (2) on the right side of the instrument panel mount.
  • Page 401 V100 E5 Bodywork • Unscrew the upper fixing screw (5) and the relative lock nut and retrieve the two T-bushings. During refitting, tighten the nut to the prescribed torque. Locking torques (N*m) Upper fixing screw (5) 10 Nm (7.38 lbf ft) •...
  • Page 402 V100 E5 Bodywork • Remove the two fixing screws (3); • Release the plastic securing the bat- tery from its mountings to the tank and remove it by bringing it toward the rear of the vehicle. • Unscrew and remove the screw (4) from the negative terminal (-).
  • Page 403 V100 E5 Bodywork ONCE REMOVED, THE BATTERY MUST BE PUT AWAY IN A SAFE PLACE OUT OF THE REACH OF CHILDREN. INSTALLATION • Follow the removal procedure in reverse order; be careful to FIRST CONNECT THE POS- ITIVE CABLE (+) and then the negative cable (-). Tail guard REAR FAIRINGS REMOVAL •...
  • Page 404 V100 E5 Bodywork • When refitting, first insert the rear tooth securing the fairing into its housing on the tail light. • Repeat the operations for the fairing on the opposite side. BODYW - 404...
  • Page 405 ABS: 284 Air filter: 71–73, 387 Battery: 110, 133, 401 Brake: 289, 291, 293, 295, 297, 299, 308, 314–316 Brake calliper: 289, 291 Brake disc: 293, 295 Brake fluid: 308 Brake pads: 297, 299 Brake pump: 314, 315 Bulbs: CAN line: 152 Cardan shaft: 250 Clutch: 85, 146, 327, 329 Coil: 141...
  • Page 406 Keys: 106 License plate holder: 385 Maintenance: 18, 59, 107, 288 Mirrors: Mudguard: 396 Oil filter: 69 Oil pressure sensor: 144 Radiator: 334 Rear wheel: 246 Recommended products: 61 SAS valve actuator: 148 Scheduled maintenance: 59 Shock absorber: Shock absorbers: 221 Side fairings: 373 Side stand: 147, 275 Side stand sensor: 147...

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