MOTO GUZZI V9 IE MIU G3 Service Station Manual
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MOTO GUZZI V9 IE MIU G3 Service Station Manual

MOTO GUZZI V9 IE MIU G3 Service Station Manual

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SERVICE STATION MANUAL
2Q000202
Engine V9 IE MIU G3

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Summary of Contents for MOTO GUZZI V9 IE MIU G3

  • Page 1 SERVICE STATION MANUAL 2Q000202 Engine V9 IE MIU G3...
  • 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

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

  • Page 7: Table Of Contents

    Engine V9 IE MIU G3 Characteristics Tightening Torques Engine RANKCASE pos. Description Type Quantity Torque Notes Central stud bolt 5-6 Nm (3.69-4.42 lb ft) Loct. DRI-LOC 211 Short stud bolt 5-6 Nm (3.69-4.42 lb ft) Loct. DRI-LOC 211 Long stud bolt 5-6 Nm (3.69-4.42 lb ft) Loct.

  • Page 8: Nm (32.45-36.14 - Lb Ft)

    Engine V9 IE MIU G3 Characteristics IMING SYSTEM COVER pos. Description Type Quantity Torque Notes SHC screw 9-11 Nm (6.64-8.11 lbf SHC screw 9-11 Nm (6.64-8.11 lbf Timing sensor screw 9-11 Nm (6.64-8.11 lbf CHAR - 8...
  • Page 9 Engine V9 IE MIU G3 Characteristics EADS COVERS pos. Description Type Quantity Torque Notes Head covers fixing screws 7-9 Nm (5.16-6.64 lb ft) Spark plugs cover TBEI fixing screws M5x12 6-8 Nm (4.42-5.90 lb ft) EADS pos. Description Type Quantity...

  • Page 10: Nm (14.75-17.70 - Lb Ft)

    Engine V9 IE MIU G3 Characteristics RANKSHAFT pos. Description Type Quantity Torque Notes Oil plug M12x1.25 15-18 Nm (11.06-13.28 Loct. 648 lb ft) Connecting rod screws - Pre-tighten- M8x1 10 Nm (7.38 lb ft) Connecting rod screws - Tightening M8x1 34-41 Nm (25.08-30.24...

  • Page 11: Nm (6.64-8.11 Lbf - Ft)

    Engine V9 IE MIU G3 Characteristics IMING SYSTEM pos. Description Type Quantity Torque Notes Tone wheel fixing screw 12-14 Nm (8.85-10.33 Loct. DRI 2045 lb ft) Chain tensioner fastener screw 9-11 Nm (6.64-8.11 lbf Rocker pins locking fork screw .. Nm (.. lb ft) Ground plate fixing screw ..
  • Page 12 Engine V9 IE MIU G3 Characteristics LUTCH pos. Description Type Quantity Torque Notes Flywheel screws .. Nm (.. lb ft) Starter sprocket fixing torx screws M6x20 9-11 Nm (6.64-8.11 lbf Loct. 243 Clutch shaft fixing nut M25z1.5 95-105 Nm Loct. 243 (70.07-77.44 lb ft)
  • Page 13 Engine V9 IE MIU G3 Characteristics OMPLETE GEAR ELECTOR ESMODROMIC pos. Description Type Quantity Torque Notes Gearbox fixing SHC screws M6x55 9-11 Nm (6.64-8.11 lbf Oil load cap M20x1.5 23-27 Nm (16.96-19.91 lb ft) Oil filter cap M28x1 25-30 Nm (18.44-22.13...
  • Page 14 Engine V9 IE MIU G3 Characteristics LTERNATOR pos. Description Type Quantity Torque Notes Magnet flywheel fixing flanged TE M12-1.25x50 100 Nm (73.76 lb ft) screw Stator fixing recessed SHC screws M6x35 9-11 Nm (6.64-8.11 lbf Loct. 243 Cable grommet plat fixing fanged TE M5x12 5-6 Nm (3.69-4.42 lb ft)
  • Page 15 Engine V9 IE MIU G3 Characteristics TARTER MOTOR pos. Description Type Quantity Torque Notes Starter motor SHC fastener screw ... Nm (... lbf ft) ECONDARY AIR SYSTEM pos. Description Type Quantity Torque Notes Red valve cover fixing SHC screws M5x16 3-4 Nm (2.21-2.95 lb ft)
  • Page 16 INDEX OF TOPICS S-TOOLS PECIAL TOOLS...
  • Page 17 Engine V9 IE MIU G3 Special tools SPECIAL TOOLS Stores code Description 020382Y Tool to extract valve cotters 020847Y Flywheel extractor 020975Y Clutch shaft nut key 19.90.71.60 Clutch shaft locking equipment 020976Y Punch for fitting the clutch control dust seal...
  • Page 18 Engine V9 IE MIU G3 Special tools Stores code Description 020978Y Punch for drive shaft secondary oil gaiter refitting 021001Y Clutch lock 020996Y Piston projection measuring tool 020995Y rocker centring pin 020128Y Piston assembly band S-TOOLS - 18...
  • Page 19 INDEX OF TOPICS NGINE...
  • Page 20 Engine V9 IE MIU G3 Engine Gearbox OMPLETE GEAR ELECTOR ESMODROMIC pos. Description Type Quantity Torque Notes Gearbox fixing SHC screws M6x55 9-11 Nm (6.64-8.11 lbf Oil load cap M20x1.5 23-27 Nm (16.96-19.91 lb ft) Oil filter cap M28x1 25-30 Nm (18.44-22.13...
  • Page 21 Engine V9 IE MIU G3 Engine EARBOX pos. Description Type Quantity Torque Notes Washers fixing countersunk head M6x12 9-11 Nm (6.64-8.11 lbf Loct. DRI 2045 screws Oil pump fixing torx screws M5x16 6-7 Nm (4.42-5.16 lb ft) Loct. DRI 2045...
  • Page 22 Engine V9 IE MIU G3 Engine 1. Thrust washer 2. 2nd speed gear on main shaft 3. Circlip 4. Thrust washer 5. 6th speed gear on main shaft 6. Floating bushing 7. Main shaft thrust washer 8. 3rd and 4th speed sliding gear on main shaft 9.

  • Page 23: Removing The Gearbox

    Engine V9 IE MIU G3 Engine Gearbox EARBOX pos. Description Type Quantity Torque Notes Neutral sensor 10 Nm (7.38 lb ft) Plate fixing screw Torx M5x16 4 Nm (2.95 lb ft) Loct. 243 Bearing block washers fixing screw TSEI 10 Nm (7.38 lb ft) Loct.
  • Page 24 Engine V9 IE MIU G3 Engine • Remove the fixing screw (2) of the gearbox, placed from the engine crankcase side • Remove the complete gearbox screw Filtro olio • Place a container with 500 cm³ (30.51 cu in) capacity under the drainage...
  • Page 25 Engine V9 IE MIU G3 Engine Disassembling the gearbox • Remove the 14 fixing screws of the gearbox • Remove the pusher plate • Remove the neutral sensor and take the gasket washer • Remove the intermediary body (1), the thrust bearing (2) and the external body (3)
  • Page 26 Engine V9 IE MIU G3 Engine • Remove the gearbox cover with a few mallet strokes • To remove the bearings fitted in the gearbox crankcases, the safety wash- er must be removed first CAUTION PAY ATTENTION WHEN REMOVING THE BEARING SAFE- TY WASHERS, THEY HAVE TWO DIFFERENT SIZES.
  • Page 27 Engine V9 IE MIU G3 Engine • Remove the gear selector shaft, the desmodromic shaft and the forks with shaft • Remove the complete gear unit To dismantle the main shaft, proceed as follows: • Remove the shim washer (1) •...
  • Page 28 Engine V9 IE MIU G3 Engine • Remove the spacer (4) • Remove the gear of the 6th gear (5) • Remove the bushing (6) • Remove the spacer (7) ENG - 28...
  • Page 29 Engine V9 IE MIU G3 Engine • Remove the gear of the 3-4th gear (8) • Remove the seeger ring (9) • Remove the spacer (10) • Remove the gear of the 5th gear (11) ENG - 29...
  • Page 30 Engine V9 IE MIU G3 Engine • Remove the bushing (12) • Remove the washer (13) from the main shaft (14) Removing the secondary shaft CAUTION REPLACE THE SEEGER RINGS DURING REFITTING To dismantle the transmission shaft, proceed as follows: •...
  • Page 31 Engine V9 IE MIU G3 Engine • Remove the bushing (3) • Remove the shim washer (4) • Remove the seeger ring (5) • Remove the gear of the 5th gear (6) ENG - 31...
  • Page 32 Engine V9 IE MIU G3 Engine • Remove the seeger ring (7) • Remove the shim washer (8) • Remove the gear of the 4th gear (9) • Remove the bushing (10) ENG - 32...
  • Page 33 Engine V9 IE MIU G3 Engine • Remove the gear of the 3rd gear (11) • Remove the bushing (12) • Remove the shim washer (13) • Remove the seeger ring (14) ENG - 33...
  • Page 34 Engine V9 IE MIU G3 Engine • Remove the gear of the 6th gear (15) • Remove the seeger ring (16) • Remove the shim washer (17) • Remove the gear of the 2nd gear (18) ENG - 34...
  • Page 35 Engine V9 IE MIU G3 Engine • Remove the bushing (19) Desmodromic demounting • Remove the gearbox selector • Remove the sliding shaft of the forks • Remove the desmodromic shaft (2) • The forks are marked with a serial number that indicated the correct posi- tioning.

  • Page 36: Disassembling The Clutch Shaft

    Engine V9 IE MIU G3 Engine • Remove the central fork No.2 (4) • Remove the lower fork No.3 (5) Disassembling the clutch shaft • Using the appropriate specific tools, re- move the clutch shaft fastening nut Specific tooling 020975Y Clutch shaft nut key 19.90.71.60 Clutch shaft locking equipment...
  • Page 37 Engine V9 IE MIU G3 Engine • Remove the oil seal from the clutch shaft CAUTION IN CASE OF OIL SEAL REPLACEMENT, USE THE SUITA- BLE PUNCH UNTIL IT REACHES THE CRANKCASE Specific tooling 020976Y Punch for fitting the clutch control dust seal •...
  • Page 38 Engine V9 IE MIU G3 Engine WEAR LIMITS Specification Desc./Quantity Maximum wear limit for the selection gear grooves 22.78 mm (0.896 in) with rollers diam. 3.5 mm (0.14 in) Minimum wear limit of the cardan shaft side secondary shaft 23.294 mm (0.9171 in) with rollers diam. 3.0 mm (0.12 in)
  • Page 39 Engine V9 IE MIU G3 Engine • Remove the spring from the index lever • Remove the washer (3) • Remove the ring (9) • Remove the seeger ring (5) ENG - 39...
  • Page 40 Engine V9 IE MIU G3 Engine • Remove the washer (6) • Remove the bushing (7) • Remove the selector spring (8) • Remove the ring (9) ENG - 40...

  • Page 41: Oil Pump

    Engine V9 IE MIU G3 Engine • Remove the bushing (10) WARNING DURING REFITTING, PAY ATTENTION TO THE CORRECT POSITIONING OF THE BUSHING, AS THE SIDES ARE NOT SYMMETRICAL • Remove the index lever (11) • Remove the bushing (12)
  • Page 42 Engine V9 IE MIU G3 Engine Removing • Remove the two oil pump fixing torx screws • Remove the complete oil pump CAUTION CHECK THE INTEGRITY OF THE GEAR TEETH OF TEFLON AND THE ROTATION FLUIDITY OF THE INTERNAL PRO- PELLERS IN THE PUMP.
  • Page 43 Engine V9 IE MIU G3 Engine IMING SYSTEM COVER pos. Description Type Quantity Torque Notes SHC screw 9-11 Nm (6.64-8.11 lbf SHC screw 9-11 Nm (6.64-8.11 lbf Timing sensor screw 9-11 Nm (6.64-8.11 lbf LTERNATOR pos. Description Type Quantity Torque...

  • Page 44: Generator Removal

    Engine V9 IE MIU G3 Engine • Remove the timing system cover sen- Generator removal ALTERNATOR COVER REMOVAL • Remove the alternator cover fixing screws • Remove the alternator cover and the gasket ROTOR REMOVAL • Remove the rotor fixing screw...
  • Page 45 Engine V9 IE MIU G3 Engine • Insert in the rotor hole the specific spacer • Place the tool (1) on the rotor, tighten the threaded pin (2) of the tool and pro- ceed with the rotor removal Specific tooling...
  • Page 46 Engine V9 IE MIU G3 Engine • Remove the washer • Remove the oil seal STATOR REMOVAL • Remove the stator wiring harness lock plate • Removing the three stator fixing screws makes it possible to disconnect ENG - 46...

  • Page 47: Generator Installation

    Engine V9 IE MIU G3 Engine Generator Installation • During refitting of the flywheel cover it is necessary to apply a great amount of threebond on the cable grommet of the stator before placing it in its seat • Check that plentiful threebond leaks...

  • Page 48: Removing The Starter Motor

    Engine V9 IE MIU G3 Engine Starter motor TARTER MOTOR pos. Description Type Quantity Torque Notes Starter motor SHC fastener screw ... Nm (... lbf ft) Removing the starter motor • Remove the starter motor fixing screws ENG - 48...
  • Page 49 Engine V9 IE MIU G3 Engine • Remove the supporting clamp of the protection (2) and the starter motor (3) Clutch side LUTCH pos. Description Type Quantity Torque Notes Flywheel screws .. Nm (.. lb ft) Starter sprocket fixing torx screws M6x20 9-11 Nm (6.64-8.11 lbf...

  • Page 50: Disassembling The Clutch

    Engine V9 IE MIU G3 Engine Disassembling the clutch • Remove the clutch cover • Lock the clutch with the specific tool Specific tooling 021001Y Clutch lock • Remove the 6 fixing screws of the clutch plate complete with starter sprocket •...
  • Page 51 Engine V9 IE MIU G3 Engine • Remove the retainer ring • Remove the thrust plate • Remove the 6 fixing screws of the lock- ing plate • Remove the reinforcement flange of the clutch thrust plate ENG - 51...

  • Page 52: Checking The Clutch Plates

    Engine V9 IE MIU G3 Engine • Remove the clutch lock complete Checking the clutch plates Clutch discs Make sure that the clutch plate is not scratched or badly worn. Check the flexible springs and the thickness of the clutch disc...
  • Page 53 Engine V9 IE MIU G3 Engine • Place the reinforcement flange of the clutch thrust plate, aligning the holes with the ones of the clutch base • Insert the 6 fastening screws complete with washers and tighten to the pre- scribed torque •...
  • Page 54 Engine V9 IE MIU G3 Engine • Place the clutch plate • Place the starter sprocket and screw the fixing screws by hand • Using the special tool for the centring of the clutch plate • Fit the assembly on the pressure plate...
  • Page 55 Engine V9 IE MIU G3 Engine Head and timing EADS COVERS pos. Description Type Quantity Torque Notes Head covers fixing screws 7-9 Nm (5.16-6.64 lb ft) Spark plugs cover TBEI fixing screws M5x12 6-8 Nm (4.42-5.90 lb ft) ENG - 55...
  • Page 56 Engine V9 IE MIU G3 Engine CYLINDER pos. Description Type Quantity Torque Notes Central stud bolt M8x143 20 Nm (14.75 lb ft) Loctite 542 Short stud bolt M10x182 42 Nm (30.98 lb ft) Long stud bolt M10x214 42 Nm (30.98 lb ft) Nuts - pre-tightening M10x1.5...

  • Page 57: Removing The Head Cover

    Engine V9 IE MIU G3 Engine IMING SYSTEM pos. Description Type Quantity Torque Notes Tone wheel fixing screw 12-14 Nm (8.85-10.33 Loct. DRI 2045 lb ft) Chain tensioner fastener screw 9-11 Nm (6.64-8.11 lbf Rocker pins locking fork screw .. Nm (.. lb ft) Ground plate fixing screw ..

  • Page 58: Removing The Cylinder Head

    Engine V9 IE MIU G3 Engine • Remove the head cover together with the gaskets • Remove the gasket from the head cov- • Check that the mating faces that contact the heads are not damaged or blistered Removing the cylinder head...
  • Page 59 Engine V9 IE MIU G3 Engine • Remove the rocker pin retainer fork • Remove the rocker pin • Remove the rocker, being careful to re- cover the Belleville spring NOTE REPEAT THE SAME PROCEDURE TO REMOVE THE OTH- ER ROCKER •...
  • Page 60 Engine V9 IE MIU G3 Engine • Unscrew and remove the compensa- tion nut of the cam tower • Undo and remove the fastening nuts of the cam tower • Remove the cam tower • Remove the three rubber O-Rings...
  • Page 61 Engine V9 IE MIU G3 Engine • Remove the complete head • Remove the cylinder head gasket • Undo and remove the engine oil pres- sure sensor • Undo and remove the secondary air valve cover ENG - 61...

  • Page 62: Cylinder Head

    Engine V9 IE MIU G3 Engine • Remove the secondary air valve • check and if necessary replace the ex- ternal rubber gasket • Remove the internal filter paying atten- tion to the direction during refitting Cylinder head Removing the valves •...
  • Page 63 Engine V9 IE MIU G3 Engine • Unscrew the tool and remove it from the head • Remove the upper cap • Remove the spring and replace it if it is out of the wear limit. Characteristic Spring free length (WEAR LIMIT) 40.5 mm (1.59 in)

  • Page 64: Checking The Rocker Arms

    Engine V9 IE MIU G3 Engine • Remove the lower cap of the spring Checking the rocker arms • Check that the bolt surface that con- tacts the rockers is not exceedingly worn. • Check the rocker to valve and rocker to rod contact surfaces.

  • Page 65: Adjusting Valve Clearance

    Engine V9 IE MIU G3 Engine Valve stem diameter (MINIMUM WEAR VALUE) 5.92 mm (0.2331 in) Valve head eccentricity (MAXIMUM ALLOWED VALUE) 0.05 mm (0.0020 in) Adjusting valve clearance • Bring the piston of the left cylinder to top dead centre making sure that the...
  • Page 66 Engine V9 IE MIU G3 Engine Rimozione ruota fonica • Remove the timing system cover • Remove the rotor • Remove the three screws that fix the tone wheel • Remove the tone wheel • Remove the spacer • Check and if necessary replace the...

  • Page 67: Removing The Chain Tensioner

    Engine V9 IE MIU G3 Engine Removing the chain tensioner • Remove the timing system cover • Remove the rotor • Remove the chain tensioner fixing screw recovering the washer • Remove the chain tensioner Chain removal • Remove the timing system cover, the...

  • Page 68: Removing The Camshaft

    Engine V9 IE MIU G3 Engine Rimozione piattello blow-by • Remove the timing system cover, the rotor and tone wheel complete with spacer • Remove the blow-by cap Removing the camshaft • Remove the timing system cover, the rotor, the tone wheel complete with...

  • Page 69: Installing The Camshaft

    Engine V9 IE MIU G3 Engine Installing the camshaft • Assemble the small ends (1) on the camshaft and lock them using the seeger (2) • Operating with the engine turned, in- sert the camshaft in the crankcase pay- ing attention that one of the holes of the...
  • Page 70 Engine V9 IE MIU G3 Engine Installazione piattello blow-by • Place the blow-by cap on the camshaft making the holes and the special tim- ing plug match Installazione catena • Fit the chain, together with timing sys- tem gear and oil pump gear...
  • Page 71 Engine V9 IE MIU G3 Engine • Fit the knurled washer and after plac- ing the nut, tighten it to the prescribed torque Installing the phonic wheel • Fit the spacer checking the correct po- sitioning on the blow-by cap, using the centring plug •...

  • Page 72: Cam Timing

    Engine V9 IE MIU G3 Engine CAUTION CHECK THE CORRECT INSTALLATION USING THE ALIGNMENT OF THE REFERENCE NOTCHES ON THE CRANKSHAFT AND ON THE TONE WHEEL Cam timing Timing • Bring the piston of the left cylinder to top dead centre making sure that the...
  • Page 73 Engine V9 IE MIU G3 Engine • Turn the pin of the oil pump, until align- ing the gear process with the pin mill- ing. • Fit the safety plug • Fit the knurled washer and after plac- ing the nut, tighten it to the prescribed torque •...
  • Page 74 Engine V9 IE MIU G3 Engine • Tighten the three fastener screws of the tone wheel to the specified torque CAUTION CHECK THE CORRECT INSTALLATION USING THE ALIGNMENT OF THE REFERENCE NOTCHES ON THE CRANKSHAFT AND ON THE TONE WHEEL Measuring air gap •...

  • Page 75: Removing The Cylinder

    Engine V9 IE MIU G3 Engine Cylinder-piston assembly CYLINDER pos. Description Type Quantity Torque Notes Central stud bolt M8x143 20 Nm (14.75 lb ft) Loctite 542 Short stud bolt M10x182 42 Nm (30.98 lb ft) Long stud bolt M10x214 42 Nm (30.98 lb ft) Nuts - pre-tightening M10x1.5...

  • Page 76: Disassembling The Piston

    Engine V9 IE MIU G3 Engine • Remove the gasket from the stud bolts Disassembling the piston • Remove one of the two retainer rings from the pin paying attention that it does not fall inside the engine • Before removing the pin, check the mounting clearance between pin and piston.

  • Page 77: Checking The Cylinder

    Engine V9 IE MIU G3 Engine Checking the cylinder • After checking for scoring, check cylin- der surface wear using a dial gauge graduated in hundredths of a millime- tre. • Measure the inner diameter of the cyl- inders at three different heights, turn the dial gauge (graduated in hun- dredths of a millimetre) 90°...

  • Page 78: Inspecting The Wrist Pin

    Engine V9 IE MIU G3 Engine Type Allowed diameter Maximum clearance between the piston and cylinder (MAXIMUM WEAR VALUE) 83.974-83.981 mm (3.3061-3.3063 in) 0.08 mm (0.0031 in) Inspecting the wrist pin • Clean off combustion residues from the piston crown and from the area above the top ring.

  • Page 79: Fitting The Piston

    Engine V9 IE MIU G3 Engine • Insert the piston rings paying attention to their mounting direction and end gap arrangement; the end gaps must be approximately 120 degrees from each other. Fitting the piston • Place the piston on the connecting rod...
  • Page 80 Engine V9 IE MIU G3 Engine • Fit a new gasket • Place the appropriate ring clamp on the piston • Place the cylinder so that the piston correctly enters the seat and as soon as the segments zone is exceeded re-...

  • Page 81: Installing The Cylinder Head

    Engine V9 IE MIU G3 Engine Installing the cylinder head • Insert the flame trap of the secondary air valve • Insert the reed valve • Fit the cover of the secondary air valve and tighten the screws to the prescri- bed torque •...
  • Page 82 Engine V9 IE MIU G3 Engine • Place the gasket • Place engine head into place • Place the three rubber O-Rings, par- ticularly apply grease to the O-Ring that will be inserted in the stud bolt in order to avoid damaging it •...
  • Page 83 Engine V9 IE MIU G3 Engine • Following a cross order "A-C-B-D" screw the fixing nuts of the cam tower to the prescribed torque • Insert and tighten the compensation nut of the cam tower to the prescribed torque •...
  • Page 84 Engine V9 IE MIU G3 Engine • Insert the rocker pin retainer fork on the pin and insert it in the seat CAUTION SLOWLY INSERT THE ROCKER PIN UNTIL THE FORK REACHES THE SUPPORT POINT ON THE CAM TOWER. THE INSERTION OF THE ROCKER PIN WITHOUT THE FORK REACHES A NON-CONTROLLED DEPTH •...
  • Page 85 Engine V9 IE MIU G3 Engine Installing the head cover • Fit the gasket on the head cover • Place the head cover together with the gaskets on the seats of the fixing screws • Place the cover fixing screws and tight-...

  • Page 86: Crankcase - Crankshaft

    Engine V9 IE MIU G3 Engine Crankcase - crankshaft RANKCASE pos. Description Type Quantity Torque Notes Central stud bolt 5-6 Nm (3.69-4.42 lb ft) Loct. DRI-LOC 211 Short stud bolt 5-6 Nm (3.69-4.42 lb ft) Loct. DRI-LOC 211 Long stud bolt 5-6 Nm (3.69-4.42 lb ft) Loct.

  • Page 87: Splitting The Crankcase Halves

    Engine V9 IE MIU G3 Engine RANKSHAFT pos. Description Type Quantity Torque Notes Oil plug M12x1.25 15-18 Nm (11.06-13.28 Loct. 648 lb ft) Connecting rod screws - Pre-tighten- M8x1 10 Nm (7.38 lb ft) Connecting rod screws - Tightening M8x1 34-41 Nm (25.08-30.24...
  • Page 88 Engine V9 IE MIU G3 Engine • Undo and remove the four long nuts from the inside of the crankcase. • Remove the upper crankcase being careful not to damage its mating face • Remove the crankshaft together with connecting rods and small ends •...

  • Page 89: Removing The Crankshaft

    Engine V9 IE MIU G3 Engine • Remove the transmitter joint • Remove the camshaft • Remove the tappets and classify them Removing the crankshaft • Remove the crankshaft connecting rods. • Unscrew the oil plug and thoroughly clean the oilway and oil passages delivering oil to con- necting rods and main journals.

  • Page 90: Inspecting The Crankcase Halves

    Engine V9 IE MIU G3 Engine Disassembling the connecting rod • Remove the screws and separate the connecting rod from the small end pay- ing attention to the reference signs and the mounting direction. • Remove the half-bearings from con- necting rods and small ends.

  • Page 91: Checking The Connecting Rod

    Engine V9 IE MIU G3 Engine Specification Desc./Quantity Clearance between shaft and bushing on timing system side 0.08 mm (0.0031 in) (MAXIMUM WEAR VALUE) Main journal diameter on clutch side (MINIMUM WEAR VAL- 43 mm (1.6929 in) Main bushing seat diameter on clutch side (WEAR LIMIT VAL- 47.17 mm (1.8571 in)
  • Page 92 Engine V9 IE MIU G3 Engine Assembling the connecting rod • Before installation, pay attention to ref- erence marks and mounting direction. • The connecting rods are available in two categories, white and blue point to be connected to the crankshaft for the crank button using the suitable bushing (present in a single class).

  • Page 93: Refitting The Crankcase Halves

    Engine V9 IE MIU G3 Engine Refitting the crankcase halves • Insert the tappets after lubricating them properly. • Operating with the engine turned, in- sert the camshaft in the crankcase pay- ing attention that one of the holes of the...
  • Page 94 Engine V9 IE MIU G3 Engine • Insert the seal ring (after lubricating it) on the crankshaft and the assembly onto the engine crankcase making sure that the connecting rods locate correctly into their seats. • House the small ends on the lower crankcase lubricating them •...
  • Page 95 Engine V9 IE MIU G3 Engine Lubrication IMING SYSTEM COVER pos. Description Type Quantity Torque Notes SHC screw 9-11 Nm (6.64-8.11 lbf SHC screw 9-11 Nm (6.64-8.11 lbf Timing sensor screw 9-11 Nm (6.64-8.11 lbf ENG - 95...
  • Page 96 Engine V9 IE MIU G3 Engine UBRICATION pos. Description Type Quantity Torque Notes Oil pump gear fastener nut M10x1.25 24-27 Nm (17.70-19.91 Loct. 243 lb ft) Oil pump fixing SHC screw M6x35 9-11 Nm (6.64-8.11 lbf Loct. DRI 2045 Oil pressure sensor M10x1 30-33 Nm (22.13-24.34...
  • Page 97 Engine V9 IE MIU G3 Engine Removing • Remove the timing system complete with oil pump gear • Remove the three fixing screws of the oil pump • Slide off the pump drive shaft (1) and remove the internal rotor (2) and the external rotor (3) •...
  • Page 98 Engine V9 IE MIU G3 Engine OIL PUMP BODY Description Values Diameter external rotor seat (MAXIMUM WEAR VALUE) 40.68 mm (1.6016 in) Diameter hole for pump drive shaft (MAXIMUM WEAR VALUE) 12.05 mm (0.4744 in) Diameter seat for roller bearings (MAXIMUM WEAR VALUE) 22.00 mm (0.8661 in)
  • Page 99 Engine V9 IE MIU G3 Engine OIL PUMP DRIVE SHAFT Description Values Diameter for pump body seat (MINIMUM WEAR VALUE) 11.95 mm (0.4705 in) Diameter seat for roller bearings (MINIMUM WEAR VALUE) 9.95 mm (0.3917 in) FITTING CLEARANCES Description Wear limit...
  • Page 100 Engine V9 IE MIU G3 Engine • Fit the oil pump in its seat, insert and tighten the three fixing screws to the specified torque Oil sump Removing the oil sump • Remove the engine oil filter fixing screw •...
  • Page 101 Engine V9 IE MIU G3 Engine • Remove the oil sump • Remove the gasket • Remove the rose pipe • Remove the cap and the relative cop- per gasket ENG - 101...
  • Page 102 Engine V9 IE MIU G3 Engine • Remove the spring • Remove the overpressure valve Refitting the oil sump • Install the overpressure valve in the engine crankcase • Insert the spring and afterwards the cap provided with a new copper gas-...
  • Page 103 Engine V9 IE MIU G3 Engine • Insert the rose pipe • Place the gasket and insert the oil sump cover • Insert and tighten the 14 fastening screws of the oil sump to the prescri- bed torque • Insert the engine oil filter together with...
  • Page 104 Engine V9 IE MIU G3 Engine • Insert and tighten the locking screw of the engine oil filter to the prescribed torque ENG - 104...
  • Page 105 Alternator: Chain: 67 Chain tensioner: 67 Clutch: 36, 49, 50, 52 Crankcase: 86, 87, 90, 93 Crankshaft: 86, 89, 90 Cylinder: 58, 62, 75, 77, 79, 81 Desmodromic drum: 38 Forks: 38 Head cover: 57, 85 Oil sump: 100, 102 Pistons: Primary shaft: 26 Secondary air system:...

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