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MOTO GUZZI V750 IE Workshop Manual

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V750 IE
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Summary of Contents for MOTO GUZZI V750 IE

  • Page 1 V750 IE workshopmanual...

  • Page 2: Introduction

    INTRODUCTION V750 IE INTRODUCTION 0 - 1...
  • Page 3 INTRODUCTION V750 IE SUMMARY 0.1. INTRODUCTION .............................. 3 0.1.1. INTRODUCTION ............................3 0.1.2. REFERENCE MANUALS .......................... 4 0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS ..................5 0 - 2...

  • Page 4: Reference Manuals

    Moto Guzzi s.p.a. reserves the right to make changes to its products at any time, barring any such changes as may alter the essential features of a product as specified in the relevant manual.
  • Page 5 INTRODUCTION V750 IE 0.1.2. REFERENCE MANUALS PARTS CATALOGUES guzzi part# (description) GU07500 OWNER’S MANUALS guzzi part# (description) 32.90.00.60 32.90.00.61 32.90.00.62 CYCLE PARTS TECHNICAL MANUAL guzzi part# (description) 32.92.01.60 32.92.01.61 32.92.01.62 32.92.01.63 32.92.01.64 32.92.01.65 ENGINE TECHNICAL MANUAL guzzi part# (description) 32.92.02.10 32.92.02.11...

  • Page 6: Abbreviations/Symbols/Conventions

    INTRODUCTION V750 IE 0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS = number < = less than > = greater than ≤ = less than or equal to ≥ = more than or equal to = approximately ∞ = infinity °C = degrees Celsius (centigrade) °F = degrees Fahrenheit ±...
  • Page 7 INTRODUCTION V750 IE T.C.E.I. = cheese-head Allen screw T.E. = hexagonal head = flat head screw = Twin Spark Ignition UPSIDE- DOWN = inverted fork = Volt = Watt Ø = Diameter 0 - 6...
  • Page 8 GENERAL INFORMATION V750 IE GENERAL INFORMATION 1 - 1...

  • Page 9: Table Of Contents

    GENERAL INFORMATION V750 IE SUMMARY 1.1. STRUCTURE OF THE MANUAL........................3 1.1.1. CONVENTIONS USED IN THE MANUAL ..................... 3 1.1.2. SAFETY WARNINGS..........................4 1.2. GENERAL RULES............................5 1.2.1. BASIC SAFETY RULES......................... 5 1.3. DANGEROUS ELEMENTS ..........................8 1.3.1. WARNINGS ............................8 1.4.

  • Page 10: Structure Of The Manual

    GENERAL INFORMATION V750 IE 1.1. STRUCTURE OF THE MANUAL 1.1.1. CONVENTIONS USED IN THE MANUAL • This manual is divided in sections and subsections, each covering a set of the most significant components. Refer to the index of sections when consulting the manual.

  • Page 11: Safety Warnings

    GENERAL INFORMATION V750 IE 1.1.2. SAFETY WARNINGS The following precautionary warnings are used throughout this manual in order to convey the following messages: Safety warning. This symbol appears, whether in the manual or on the vehicle itself, to indicate a personal injury hazard.

  • Page 12: General Rules

    GENERAL INFORMATION V750 IE 1.2. GENERAL RULES 1.2.1. BASIC SAFETY RULES CARBON MONOXIDE Should it be necessary to perform some operations with the vehicle running, make sure to work outdoors or in a well- aerated room. Avoid starting the engine in closed or badly-ventilated rooms.
  • Page 13 GENERAL INFORMATION V750 IE HYDROGEN GAS AND BATTERY ELECTROLYTE DANGER The battery electrolyte is a toxic, caustic substance containing sulphuric acid and thus able to cause severe burns in case of contact. Always wear tight gloves and protective clothes when handling this fluid.
  • Page 14 NOTE All bearings must rotate freely with no hardness or noise. Replace any bearings that do not meet these requirements. Use ORIGINAL Moto Guzzi SPARE PARTS only. Use the specified lubricants and consumables. Where possible, lubricate a part before assembly.

  • Page 15: Dangerous Elements

    GENERAL INFORMATION V750 IE 1.3. DANGEROUS ELEMENTS 1.3.1. WARNINGS FUEL DANGER The fuel used to operate engines is highly flammable and becomes explosive under particular conditions. Refuelling and engine service should take place in a well-ventilated area with the engine stopped. Do not smoke when refuelling or in the proximity of sources of fuel vapours.
  • Page 16 GENERAL INFORMATION V750 IE BRAKE FLUID NOTE This vehicle is fitted with front and rear disc brakes. Each braking system is operated by an independent hydraulic circuit. The information provided below applies to both braking systems. DANGER Do not use the vehicle in case brakes are worn out or do not work properly! The brakes are the parts that most ensure your safety and for this reason they must always be perfectly working.
  • Page 17 GENERAL INFORMATION V750 IE COOLANT DANGER Coolant is toxic when ingested and is an irritant, contact with eyes or skin may cause irritation. In the event of contact with eyes, rinse repeatedly with abundant water and seek medical advice. In the event of ingestion, induce vomiting, rinse mouth and throat with abundant water and seek medical advice immediately.
  • Page 18 GENERAL INFORMATION V750 IE TYRES WARNING If tyres are excessively inflated, the vehicle will be hard and uneasy to ride, thus making you feel not at your ease. In addition the roadworthiness, mainly on wet surfaces and during cornering, will be impaired.

  • Page 19: Running-In

    GENERAL INFORMATION V750 IE 1.4. RUNNING-IN 1.4.1. RUNNING-IN RECOMMENDATIONS The running-in of the engine is essential to ensure its duration and correct functioning. If possible, drive on hilly roads and/or roads with many bends, so that the engine, the suspensions and the brakes undergo a more effective running-in.

  • Page 20: Location Of Serial Numbers

    GENERAL INFORMATION V750 IE 1.5. LOCATION OF SERIAL NUMBERS 1.5.1. LOCATION OF SERIAL NUMBERS These numbers are necessary for vehicle registration. IMPORTANT: Altering the identification numbers of vehicle or engine is a legal offence punishable by heavy fines and penalties. In addition, altering the frame number (VIN) results in immediate warranty invalidation.
  • Page 21 PERIODIC MAINTENANCE V750 IE PERIODIC MAINTENANCE 2 - 1...
  • Page 22 PERIODIC MAINTENANCE V750 IE SUMMARY 2.1. GENERAL TECHNICAL INFORMATION ......................3 2.1.1. TECHNICAL DATA............................ 3 2.1.2. TABLE OF LUBRICANTS.......................... 4 2.1.3. TIGHTENING TORQUES .......................... 5 2.1.4. SPECIAL TOOLS ............................6 2 - 2...

  • Page 23: General Technical Information

    PERIODIC MAINTENANCE V750 IE 2.1. GENERAL TECHNICAL INFORMATION 2.1.1. TECHNICAL DATA ENGINE – TRANSMISSION ENGINE Type two-cylinder 4-stroke Number of cylinders Cylinder layout: 90° V Pistons forged, two compression rings, one oil control ring Bore 80 mm (3.15 in) Stroke 74 mm (2.91 in)

  • Page 24: Table Of Lubricants

    PERIODIC MAINTENANCE V750 IE 2.1.2. TABLE OF LUBRICANTS LUBRICANT PRODUCT Engine oil RECOMMENDED: RACING 4T Alternatively, use brand name oil complying with or exceeding CCMC G-4 A.P.I. S.G. specifications. Transmission oil RECOMMENDED: TRUCK GEAR 85 W 140 Gearbox oil RECOMMENDED:...

  • Page 25: Tightening Torques

    PERIODIC MAINTENANCE V750 IE 2.1.3. TIGHTENING TORQUES TIGHTENING DESIGNATION TORQUES (Nm) CYLINDER HEADS Cylinder head covers fixing screws Spark plugs CRANKCASE AND COVERS Cylinder heads-barrels to crankcase fixing nut (M10) 40÷42 Cylinder heads-barrels to crankcase fixing nut (M8) 28÷30 Crankcases joining nuts (M8) 22÷25...

  • Page 26: Special Tools

    PERIODIC MAINTENANCE V750 IE 2.1.4. SPECIAL TOOLS 2 - 6...
  • Page 27 PERIODIC MAINTENANCE V750 IE Key: Position Tool designation and application Part number Bush for fitting oil seal on secondary shaft 19 92 73 00 Tool for fitting oil seal on timing cover (crankshaft) 19 92 72 20 Valves disassembly / assembly tool...
  • Page 28 GEARBOX V750 IE GEARBOX 3 - 1...
  • Page 29 GEARBOX V750 IE SUMMARY 3.1. GEARBOX HOUSING ............................3 3.1.1. DISASSEMBLY ............................3 3.1.2. REASSEMBLY ............................7 3.1.3. TIGHTENING TORQUES ........................11 3.2. CLUTCH HOUSING............................12 3.2.1. DISASSEMBLY ............................12 3.2.2. REASSEMBLY ............................15 3.2.3. TIGHTENING TORQUES ........................19 3.3.

  • Page 30: Gearbox Housing

    GEARBOX V750 IE 3.1. GEARBOX HOUSING 3.1.1. DISASSEMBLY • Mount clutch shaft on housing so that the gear engages the main shaft gear. • Insert the prescribed holding tool in the clutch shaft grooves • Remove the intermediate gear blocking nut and take out the washer.
  • Page 31 GEARBOX V750 IE • Remove gear and clutch shaft. • Unscrew breather plug with its pawl. 3 - 4...
  • Page 32 GEARBOX V750 IE • Unscrew and remove idle gear indicator. • Unscrew gearbox cover bolts and remove it with the help of a mallet. • Loosen counternut and remove the eccentric screw to position preselector. 3 - 5...
  • Page 33 GEARBOX V750 IE • Slide preselector out and remove preselector blocking ring. • After loosening securing screws of blocking plates carry on with unit removal complete with gear, shafts and forks. 3 - 6...

  • Page 34: Reassembly

    GEARBOX V750 IE 3.1.2. REASSEMBLY Preselector reassembly • After remounting the unit complete with shafts on gearbox cover, insert the spring and insert the two tangs on the preselector peg making sure the distance between the two tangs is equal both on the peg and at tangs ends.
  • Page 35 GEARBOX V750 IE • Reassemble preselector spacer. • Place preselector on the cover making sure that the two spring tangs are inserted in the hollow of the adjustment screw, then rotate the screw by 90ø and tighten counternut. • Remount gasket, tighten securing screws of gearbox housing cover to prescribed torque.
  • Page 36 GEARBOX V750 IE • Insert gear with relative washer on main shaft of gear and tighten securing nut to prescribed torque and stake with punch. 3 - 9...
  • Page 37 GEARBOX V750 IE 3 - 10...

  • Page 38: Tightening Torques

    GEARBOX V750 IE 3.1.3. TIGHTENING TORQUES GEARBOX Primary shaft fixing nuts 65 Nm Cover to gearbox fixing screws 10 Nm Gearbox to clutch housing cover fixing screws 10 Nm Index lever fixing screw nut. 6 Nm 3 - 11...

  • Page 39: Clutch Housing

    GEARBOX V750 IE 3.2. CLUTCH HOUSING 3.2.1. DISASSEMBLY • Once the gearbox/clutch housing has been fixed to the vice-held support, use the nut holding tool to loosen the nut by turning the shaft with the appropriate tool. • Remove the Allen screws locking the clutch housing to gearbox.
  • Page 40 GEARBOX V750 IE • Disconnect and remove housing, complete with clutch shaft, by lightly hitting housing sides.. • Remove gasket. • Remove the three screws with washers and take off bearing blocking plate. 3 - 13...
  • Page 41 GEARBOX V750 IE • Unscrew clutch shaft securing nut. • Take out clutch shaft, remove clutch and blocking ring. 3 - 14...

  • Page 42: Reassembly

    GEARBOX V750 IE 3.2.2. REASSEMBLY • Insert clutch shaft with the help of a plastic mallet, remount sieger and then blocking ring. 3 - 15...
  • Page 43 GEARBOX V750 IE • Position blocking plate and tighten screws with washer after covering them with thread locking paste. • Position clutch housing gasket and place clutch housing in its seat. 3 - 16...
  • Page 44 GEARBOX V750 IE • Tighten Allen screws, external screws and tighten to prescribed torque. • Tighten clutch shaft nut using the appropriate tool and stake. • Insert breather plug. 3 - 17...
  • Page 45 GEARBOX V750 IE • Screw in gear in idle indicator. • Insert clutch push rod in shaft with the greater diameter towards the control lever. 3 - 18...
  • Page 46 GEARBOX V750 IE 3.2.3. TIGHTENING TORQUES CLUTCH Clutch shaft fixing nut 100 Nm 3 - 19...

  • Page 47: Gear

    GEARBOX V750 IE 3.3. GEARBOX 3.3.1. GEAR Primary gear shaft 25. Clearance washer Gear 26. Bearing Thrust washer 27. Spacer Circlip 28. Gutter Gear 29. Circlip Gear 30. Washer Roller cage 31. Washer Gear 32. Shift cam Idle gear 33. Pin 10.
  • Page 48 ENGINE V750 IE ENGINE 4 - 1...
  • Page 49 ENGINE V750 IE SUMMARY 4.1. GEARBOX AND STARTER MOTOR REMOVAL .................... 4 4.1.1. GEARBOX REMOVAL FROM ENGINE....................4 4.1.2. STARTER MOTOR REMOVAL......................5 4.1.3. OIL SUCTION PIPE DETACHMENT FROM BLOCK................6 4.1.4. TIGHTENING TORQUES ........................7 4.2. CYLINDER HEAD COVERS..........................8 4.2.1.
  • Page 50 ENGINE V750 IE 4.13. OIL SUMP ..............................91 4.13.1. OIL SUMP DISASSEMBLY........................91 4.13.2. OIL SUMP CHECK ..........................94 4.13.3. REASSEMBLY............................95 4.13.4. OIL PUMP DISASSEMBLY........................97 4.13.5. OIL PUMP INSPECTION ........................99 4.13.6. OIL PUMP REASSEMBLY........................101 4.13.7. OIL PRESSURE ADJUSTMENT VALVE DISASSEMBLY..............102 4.13.8. OIL PRESSURE ADJUSTMENT VALVE ASSEMBLY................103 4.13.9.

  • Page 51: Engine V750 Ie

    ENGINE V750 IE 4.1. GEARBOX AND STARTER MOTOR REMOVAL 4.1.1. GEARBOX REMOVAL FROM ENGINE • Remove gearbox securing screws from engine. • Remove gearbox. 4 - 4...

  • Page 52: Starter Motor Removal

    ENGINE V750 IE 4.1.2. STARTER MOTOR REMOVAL • Remove starter motor securing screws. • Remove starter motor. 4 - 5...

  • Page 53: Oil Suction Pipe Detachment From Block

    ENGINE V750 IE 4.1.3. OIL SUCTION PIPE DETACHMENT FROM BLOCK • Remove oil fume suction pipe from block. 4 - 6...

  • Page 54: Tightening Torques

    ENGINE V750 IE 4.1.4. TIGHTENING TORQUES ELECTRIC STARTING Starter motor fixing screws 25 Nm 4 - 7...

  • Page 55: Cylinder Head Covers

    ENGINE V750 IE 4.2. CYLINDER HEAD COVERS 4.2.1. CYLINDER HEAD COVERS REMOVAL • Remove screws and take off head covers and head gaskets. 4 - 8...

  • Page 56: Check

    ENGINE V750 IE 4.2.2. CHECK • Check for damage to contact surfaces to heads and for blowholes. 4 - 9...

  • Page 57: Reassembly

    ENGINE V750 IE 4.2.3. REASSEMBLY • Change cover gaskets, reassemble covers on heads. • Lock screws crosswise with dynamometric spanner to the prescribed torque value. 4 - 10...

  • Page 58: Tightening Torques

    ENGINE V750 IE 4.2.4. TIGHTENING TORQUES CYLINDER HEADS Cylinder head covers fixing screws 10 Nm Spark plugs 25 Nm 4 - 11...

  • Page 59: Timing

    ENGINE V750 IE 4.3. TIMING 4.3.1. ENGINE FRONT COVER DISASSEMBLY • Remove securing screws and take protective covers off alternator unit. 4 - 12...

  • Page 60: Alternator Disassembly

    ENGINE V750 IE 4.3.2. ALTERNATOR DISASSEMBLY • Remove screws securing stator to timing cover and slide stator out. • Unscrew the rotor to crankshaft fixing nut, withdraw the rotor and remove the key. 4 - 13...
  • Page 61 ENGINE V750 IE 4 - 14...

  • Page 62: Rev And Stroke Sensor Removal

    ENGINE V750 IE 4.3.3. REV AND STROKE SENSOR REMOVAL • Remove the two securing screws and slip stroke sensor out. 4 - 15...

  • Page 63: Timing Cover Removal

    ENGINE V750 IE 4.3.4. TIMING COVER REMOVAL • Remove securing screws and take off timing cover with its gasket. • Remove chain stretcher. • Remove securing screw of sound wheel and take it out. 4 - 16...
  • Page 64 ENGINE V750 IE • Remove the two screws, timing gear to shaft, chain and oil pump gear. 4 - 17...

  • Page 65: Timing Check

    ENGINE V750 IE 4.3.5. TIMING CHECK ROCKER ARM DISASSEMBLY • Remove piston rings and slip the two rocker arms and the oil delivery union out. 4 - 18...
  • Page 66 ENGINE V750 IE • Check that pin surface in contact with rocker arms is not overworn. • Check contact surfaces of both valve rocker arm and rocker arm rod. ROCKER ARM REASSEMBLY • Check that longitudinal milling is set towards oil delivery duct.
  • Page 67 ENGINE V750 IE • Check that rocker arm push rods are straight, and that end contact surfaces do not show signs of seizing. If so, replace them. • An easy way to check if the pressed ends on the rods (pads) have become slack is to drop them from a short distance onto a flat surface;...

  • Page 68: Timing Reassembly

    ENGINE V750 IE 4.3.6. TIMING REASSEMBLY • Put left cylinder at top dead centre by checking that reference on driving shaft gear is at top of its perpendicular axis. • Position timing shaft with gear reference pin pointing downwards. •...
  • Page 69 ENGINE V750 IE • Tighten oil pump nut with oil pump shaft held still. 4 - 22...
  • Page 70 ENGINE V750 IE • Insert belt stretcher and tighten with dynamometric spanner to prescribed torque. 4 - 23...

  • Page 71: Timing Check

    ENGINE V750 IE 4.3.7. TIMING CHECK • After positioning the goniometer and centesimal comparator: put the cylinder at top dead centre in compression phase and check exact positioning by following the centesimal comparator readings. • Zero goniometer using top dead centre on indicator as reference.
  • Page 72 ENGINE V750 IE • Turn clockwise until contact between rod and rocker arm is reached and on goniometer check intake valve advance with respect to top dead centre. • Continue to turn until rod is free, read the value representing retard of the valve closing with respect to bottom dead centre.

  • Page 73: Sound Wheel Assembly

    ENGINE V750 IE 4.3.8. SOUND WHEEL ASSEMBLY • Sound wheel position is given by the dowel on timing shaft. • Position sound wheel by checking correct insertion on timing shaft (see notch) tighten using dynamometric spanner to prescribed torque. •...

  • Page 74: Air Gap Measurement And Sensor Reassembly

    ENGINE V750 IE 4.3.9. AIR GAP MEASUREMENT AND SENSOR REASSEMBLY • Insert a flat washer on the sensor to measure thickness. • Position the sensor on timing cover and contact it with the sound wheel. • Use a thickness gauge to measure clearance between securing plate and cover.
  • Page 75 ENGINE V750 IE • Remove the washer and insert the sensor after covering securing plate surface with sealant paste and tighten the screws to torque. 4 - 28...

  • Page 76: Alternator Reassembly

    ENGINE V750 IE 4.3.10. ALTERNATOR REASSEMBLY • Insert the contact washer, locking spline and rotor, and tighten the screw nut with the dynamometric spanner to torque. 4 - 29...
  • Page 77 ENGINE V750 IE • Insert stator and its cover and tighten the three screws. • Insert stator cover. 4 - 30...

  • Page 78: Timing Data

    ENGINE V750 IE 4.3.11. TIMING DATA Intake: opens 18° before T.D.C.; closes 50° after B.D.C. Exhaust: opens 53° before B.D.C.; closes 15° after T.D.C. Valves clearance for timing check 1 mm (0,039). Valves clearance for operation: intake 0.15 mm (0,0059);;...

  • Page 79: Tightening Torques

    ENGINE V750 IE 4.3.12. TIGHTENING TORQUES TIMING Camshaft to crankcase fixing connection 30 Nm Timing gear to camshaft fixing screws 25 Nm Phonic wheel fixing screw 25 Nm 4 - 32...

  • Page 80: Clutch

    ENGINE V750 IE 4.4. CLUTCH 4.4.1. DISASSEMBLY OF CLUTCH PLATE AND DISK • Mount prescribed engine flywheel stopping tool on block. • Unscrew clutch plate securing screws and remove it complete with starter ring. 4 - 33...
  • Page 81 ENGINE V750 IE • Remove clutch disk. 4 - 34...

  • Page 82: Check

    ENGINE V750 IE 4.4.2. CHECK • Check clutch disk for scratches or overwear. • Check antijerk rings and that clutch disk thickness is not less than value prescribed: if so, clutch disk must be replaced. • Check clutch disk ring gears of rim and contact surface for wear.

  • Page 83: Clutch Plate And Disk Assembly

    ENGINE V750 IE 4.4.3. CLUTCH PLATE AND DISK ASSEMBLY • Once the flywheel stopping tool has been inserted. • insert cup with relative blocking ring. • Position appropriate tool to centre clutch disk on plate and position disk in seat.
  • Page 84 ENGINE V750 IE • Fix the assembly on flywheel thrust plate by tightening screws to torque. 4 - 37...

  • Page 85: Tightening Torques

    ENGINE V750 IE 4.4.4. TIGHTENING TORQUES CLUTCH Clutch shaft fixing nut 100 Nm 4 - 38...

  • Page 86: Engine Thrust Plate Flywheel

    ENGINE V750 IE 4.5. ENGINE THRUST PLATE FLYWHEEL 4.5.1. FLYWHEEL DISASSEMBLY • Remove stop ring and engage-disengage cup. • Remove screws securing thrust plate flywheel to driving shaft, then take it out. 4 - 39...
  • Page 87 ENGINE V750 IE 4 - 40...

  • Page 88: Check

    ENGINE V750 IE 4.5.2. CHECK • Check that flywheel surfaces in contact with disk are not scratched. • Check that driving shaft contact surfaces are not deformed. If so, flywheel must be replaced. 4 - 41...

  • Page 89: Flywheel Thrust Plate Reassembly

    ENGINE V750 IE 4.5.3. FLYWHEEL THRUST PLATE REASSEMBLY • When reassembling flywheel thrust plate on driving shaft make sure that "yellow" mark on driving shaft is perfectly in line with groove on engine flywheel. • Tighten the screws and insert the appropriate flywheel stopping tool.
  • Page 90 ENGINE V750 IE 4 - 43...

  • Page 91: Tightening Torques

    ENGINE V750 IE 4.5.4. TIGHTENING TORQUES CONNECTING ROD GROUP Rods fixing screws 30÷32 Nm Flywheel to crankshaft fixing screws 40 Nm Ring gear fixing screws 10 Nm 4 - 44...

  • Page 92: Engine Head

    ENGINE V750 IE 4.6. ENGINE HEAD 4.6.1. ENGINE HEAD DISASSEMBLY • Crosswise unscrew nuts at block securing heads, cylinders and rocker arm pins. • Remove top spacers, rocker arms complete with pins, bottom spacers, rocker arm control push rods and slide heads out of stud bolts.
  • Page 93 ENGINE V750 IE 4 - 46...

  • Page 94: Disassembly Of Head Valves

    ENGINE V750 IE 4.6.2. DISASSEMBLY OF HEAD VALVES • Place the prescribed tool on the top cap of the valve to be removed and at the centre of valve mushroom. • Close tool by compressing the spring and hit the head of the tool with a mallet to remove the two cotters from top cap.
  • Page 95 ENGINE V750 IE • Slip out top cap, spring and then valve. 4 - 48...

  • Page 96: Valve Guide From Heads Disassembly

    ENGINE V750 IE 4.6.3. VALVE GUIDE FROM HEADS DISASSEMBLY • Remove valve guide gaskets and take out bottom spring cap. NOTE Valve guides must be replaced when wear is such that valve replacement alone is insufficient to eliminate clearance between valve stem and internal hole of valve guide.

  • Page 97: Valve Seat Reassembly And Check

    ENGINE V750 IE 4.6.4. VALVE SEAT REASSEMBLY AND CHECK • Hit the valve guides back into place with punch and mallet from the outside towards the inside; it is advisable to preheat the head to around 60°C. • Once the valve guides are back in place rectify them with a reamer to obtain internal diameter measurement given in table.
  • Page 98 ENGINE V750 IE INTAKE A ø mm (in) (theoretical) (theoretical) mm (in) mm (in) mm (in) ø 32,0÷32,25 1,42 (1.3386) (0.0559) (0.0394) (1.2598÷1.2697) EXHAUST A ø mm (in) (theoretical) (theoretical) mm (in) mm (in) mm (in) ø 27,72÷27,97 1,14 (1.1811) (0.0630)

  • Page 99: Valve Seat Rectification

    ENGINE V750 IE 4.6.5. VALVE SEAT RECTIFICATION NOTE Valve seat rectification after valve guide replacement or when valve seat is not tight rectification must be carried out. • Once the pilot tool has been chosed put it in the valve guide and lock in place.
  • Page 100 ENGINE V750 IE • Repeat operation with appropriate mill to restore valve blocking seat width. • Remove all tools used when operation is completed. • Put back spring bottom seats and use the prescribed tool to insert blocking gaskets on valve guide.
  • Page 101 ENGINE V750 IE 4 - 54...

  • Page 102: Spring Pack Inspection

    ENGINE V750 IE 4.6.6. SPRING PACK INSPECTION With the assembly (cups, springs, valves and half-cones) installed on the heads, the external springs must be compressed by 36 mm (1.4173 in). Note that at their fully open position the valves must have an additional 1 mm (0.039 in) excursion before the internal spring is completely compressed.
  • Page 103 ENGINE V750 IE SPRING CHARACTERISTICS DESCRIPTION UNIT VALUE External diameter mm (in) Internal diameter mm (in) 17,8 ± 0,2 (0.7007 ± 0.0079) Wire diameter mm (in) 3,4 ± 0,03 (0.1338 ± 0.0012) Free length mm (in) 43,6 (1.7165) Solid length mm (in) 27,5 (1.0827)

  • Page 104: Engine Head Reassembly

    ENGINE V750 IE 4.6.7. ENGINE HEAD REASSEMBLY • Position new gasket and put engine head in seat. • Insert bottom spacers of rocker arms, rocker arm push rods, rocker arms and top spacers with all relative nuts. 4 - 57...
  • Page 105 ENGINE V750 IE • Crosswise lock the nuts to prescribed torque. 4 - 58...

  • Page 106: Tightening Torques

    ENGINE V750 IE 4.6.8. TIGHTENING TORQUES CYLINDER HEADS Cylinder head covers fixing screws 10 Nm Spark plugs 25 Nm 4 - 59...

  • Page 107: Cylinders

    ENGINE V750 IE 4.7. CYLINDERS 4.7.1. CYLINDERS DISASSEMBLY • Slip cylinders with their gaskets out of stud bolts. • Remove the O ring between block and cylinder. 4 - 60...

  • Page 108: Check

    ENGINE V750 IE 4.7.2. CHECK • After checking scoring, use a centesimal comparator to check for cylinder surface wear. • Measure inside cylinder diameter at three heights (insert legend) by revolving centesimal comparator by 90ø repeat measurements; Centesimal comparator must be previously zeroed on a ring gauge.

  • Page 109: Cylinder Assembly

    ENGINE V750 IE 4.7.3. CYLINDER ASSEMBLY • Check that compression ring notches are staggered at angles of about 120 degrees between each other. • Once the new gasket is in place and the ring is inserted in its seat on the block, put an adequate market available ring-tightener on the piston.
  • Page 110 ENGINE V750 IE • Once past the segment area remove ring-tightener from piston and insert cylinder in its seat. 4 - 63...

  • Page 111: Tightening Torques

    ENGINE V750 IE 4.7.4. TIGHTENING TORQUES CRANKCASE AND COVERS Cylinder heads-barrels to crankcase fixing nut (M10) 40÷42 Nm Cylinder heads-barrels to crankcase fixing nut (M8) 28÷30 Nm Crankcases joining nuts (M8) 22÷25 Nm Crankcases joining nuts (M10) 40÷42 Nm Timing cover fixing screws...

  • Page 112: Pistons

    ENGINE V750 IE 4.8. PISTONS 4.8.1. PISTONS DISASSEMBLY • After protecting cylinder seat, remove the two gudgeon retaining springs. • Use the screw of the prescribed tool to slip gudgeon out and remove piston. NOTE When overhauling carry out decarbonization of piston crown and piston ring housings.

  • Page 113: Check

    ENGINE V750 IE 4.8.2. CHECK • First check for superficial scoring and then check wear of the cylinder bore surfaces using a dial gauge • Measure the inside diameter of the cylinder bore at three different heights then turn the dial gauge through 90°...
  • Page 114 ENGINE V750 IE • Check that the selection mark and assembly arrows are punch marked on the piston. Piston diameter selection GRADE “D” GRADE “E” GRADE “F” mm (in) mm (in) mm (in) 79,940 ÷ 79,950 79,950 ÷ 79,960 79,960 ÷ 79,970 (3.1472 ÷...

  • Page 115: Piston Reassembly

    ENGINE V750 IE 4.8.3. PISTON REASSEMBLY • In reassembling piston to con rod eye, heat piston in oil bath to about 60°C (140°F), to slightly dilate it so gudgeon is easier to put back. • Insert blocking spring in piston and fit appropriate tool on piston to insert gudgeon.
  • Page 116 ENGINE V750 IE 4 - 69...

  • Page 117: Compression Rings And Scraper Ring

    ENGINE V750 IE 4.9. COMPRESSION RINGS AND SCRAPER RING 4.9.1. DISASSEMBLY • Remove compression rings and scraper ring. NOTE to avoid breaking, rings must not be stretched more than is necessary to slip them off piston. 4 - 70...

  • Page 118: Compression Ring Check

    ENGINE V750 IE 4.9.2. COMPRESSION RING CHECK • Use a feeler gauge to check that the assembly clearance between ring and ring groove on the piston is as specified. top compression ring mm 0.030 ÷ 0.062 (in 0.0012 ÷ 0.0024);...

  • Page 119: Compression Ring And Scraper Ring Reassembly

    ENGINE V750 IE 4.9.3. COMPRESSION RING AND SCRAPER RING REASSEMBLY • Insert compression rings according to notches and ring assembly direction; rings must be staggered at angles of about 120 degrees between each other. 4 - 72...

  • Page 120: 4.10. Engine Block

    ENGINE V750 IE 4.10. ENGINE BLOCK 4.10.1. ENGINE BLOCK DISASSEMBLY • Remove the four column nuts from inside the block and the six nuts outside. • Insert a bar in engine union tie rod seat to chassis, then use a plastic mallet to lightly hit the rod to get the two halfblocks to separate.
  • Page 121 ENGINE V750 IE • Remove top block taking care not to damage contact surface. • Remove driving shaft complete with connecting rods and halfbearings. • Unscrew oil pressure sensor from top block and remove timing shaft check bushing and then slip out the shaft and tappets and classify them.
  • Page 122 ENGINE V750 IE 4 - 75...

  • Page 123: Check

    ENGINE V750 IE 4.10.2. CHECK • Check that junction surfaces are whole, not either dented or scratched. Remove liquid sealant with trichloroethylene. • Check that stud bolt threading is not dented or stripped. If so, replace stud bolts. • Clean all lubricant channels of the two blocks with compressed air.

  • Page 124: Engine Block Reassembly

    ENGINE V750 IE 4.10.3. ENGINE BLOCK REASSEMBLY • Lubricate and reinsert tappets. • Reposition timing shaft in top block seat and lubricate and lock timing shaft-stopper union into place. • Insert halfbearing on timing and flywheel sides with shoulders on top block and lubricate parts assembled.
  • Page 125 ENGINE V750 IE • Insert lubricated blocking ring on driving shaft and reposition the assembly on engine block making sure con rods are correctly inserted in their seats. 4 - 78...
  • Page 126 ENGINE V750 IE • Put lubricated halfbearings back in their housings in bottom block, cover block junction surfaces with prescribed fluid sealant. • Couple the two blocks making sure the two surfaces adhere perfectly by lightly hitting them with a mallet and crosswise tighten the four centre stud bolts and external nuts to the prescribed torque.
  • Page 127 ENGINE V750 IE 4 - 80...

  • Page 128: Tightening Torques

    ENGINE V750 IE 4.10.4. TIGHTENING TORQUES BASAMENTO E COPERCHI Dado fissaggio teste -cilindri al basamento (M10) 40÷42 Nm Dado fissaggio teste-cilindri al basamento (M8) 28÷30 Nm Dadi unione basamenti (M8) 22÷25 Nm Dadi unione basamenti (M10) 40÷42 Nm Viti di fissaggio coperchio distribuzione...

  • Page 129: 4.11. Con Rods

    ENGINE V750 IE 4.11. CON RODS 4.11.1. CON RODS DISASSEMBLY • Once the driving shaft, complete with con rods, has been removed from the top block, remove screws and separate con rod from small end making sure reference marks and assembly direction are followed.

  • Page 130: Con Rod Clearance Check

    ENGINE V750 IE 4.11.2. CON ROD CLEARANCE CHECK • With a micrometer check con rod pin diameter measurement on the orthogonal axes and in the working area of the halfbearings. Check bearing housing measurement on both timing and flywheel sides.

  • Page 131: Con Rod Reassembly

    ENGINE V750 IE 4.11.3. CON ROD REASSEMBLY • Before assembling check reference marks assembly direction. • Reassemble con rods in driving shaft seat on con rod pin by tightening the screws to the prescribed torque. CON ROD SHIM CHECK Make sure that assembly clearance of con rods and driving shaft shoulders complies with prescribed values: mm 0,265÷0,515 (in 0.0104 ÷...

  • Page 132: Tightening Torques

    ENGINE V750 IE 4.11.4. TIGHTENING TORQUES CONNECTING ROD GROUP Rods fixing screws 30÷32 Nm Flywheel to crankshaft fixing screws 40 Nm Ring gear fixing screws 10 Nm 4 - 85...

  • Page 133: 4.12. Driving Shaft

    ENGINE V750 IE 4.12. DRIVING SHAFT 4.12.1. DRIVING SHAFT DISASSEMBLY • Disassemble driving shaft con rods. • Unscrew oil plug and thoroughly clean oil ducts and passages to con rods and main journals. 4 - 86...
  • Page 134 ENGINE V750 IE 4 - 87...

  • Page 135: Driving Shaft Check

    ENGINE V750 IE 4.12.2. DRIVING SHAFT CHECK • Apply thread locking paste to plug thread and screw it firmly back into place. • Clean lubricant passages with compressed air. NOTE Driving shaft is nitrided therefore cannot be ground; if wear, ovalization or deep scratching has occurred driving shaft must be replaced.
  • Page 136 ENGINE V750 IE Diameter of flywheel side crankshaft journal Normal (production) mm (in) 39,995÷40,011 (1.5746 ÷ 1.5752) Thickness of thrust half washer on flywheel side main bearing Normal (production) mm (in) 2,310÷2,360 (0.0909 ÷ 0.0929) Main bearing journal to shell clearance Normal (production) mm (in) 0,35÷0,40...
  • Page 137 ENGINE V750 IE 4.12.3. TIGHTENING TORQUES CONNECTING ROD GROUP Rods fixing screws 30÷32 Nm Flywheel to crankshaft fixing screws 40 Nm Ring gear fixing screws 10 Nm 4 - 90...

  • Page 138: 4.13. Oil Sump

    ENGINE V750 IE 4.13. OIL SUMP 4.13.1. OIL SUMP DISASSEMBLY • Remove oil filter securing screw to sump. • Remove cartridge filter. • Remove screws securing oil sump to engine block and take sump out and slide gasket off. 4 - 91...
  • Page 139 ENGINE V750 IE • Remove oil level indicator. • Flatten safety plate, remove mesh filter blocking screw and filter from oil sump. 4 - 92...
  • Page 140 ENGINE V750 IE 4 - 93...

  • Page 141: Oil Sump Check

    ENGINE V750 IE 4.13.2. OIL SUMP CHECK • Check mesh filter for dirt. If so, wash and clean with compressed air. 4 - 94...

  • Page 142: Reassembly

    ENGINE V750 IE 4.13.3. REASSEMBLY • Insert filter, safety plate and tighten securing screw. • Bend safety plate. • Position gasket between oil sump and block (Always replace gasket). Take care to position gasket correctly since incorrect assembly causes anomalous oil circulation.
  • Page 143 ENGINE V750 IE • Crosswise tighten sump screws and lock them with dynamometric spanner to prescribed torque. • Insert filter cartridge and tighten screw to prescribed torque. 4 - 96...

  • Page 144: Oil Pump Disassembly

    ENGINE V750 IE 4.13.4. OIL PUMP DISASSEMBLY • After disassembling timing, unscrew Allen screws and remove oil pump from engine block. Disassemble pump as follows: • Remove locking spline. • Take pump drive shaft out with inside rotor attached. •...
  • Page 145 ENGINE V750 IE 4 - 98...

  • Page 146: Oil Pump Inspection

    ENGINE V750 IE 4.13.5. OIL PUMP INSPECTION OIL PUMP BODY Check that the faces and internal seats of the pump body are not scored, damaged or dented. Oil pump data: ø of seat for external rotor 40.650÷40.675 mm (in 1.6004 ÷ 1.6014);...
  • Page 147 ENGINE V750 IE INTERNAL ROTOR Check that the internal and external surfaces and the faces are not scored or damaged, otherwise renew both rotors. Internal rotor data: external ø 29.745÷29.770 mm (in 1.1711 ÷ 1.1720); ø of bore for pump drive shaft 12.000÷12.018 mm (in 0.4724 ÷...

  • Page 148: Oil Pump Reassembly

    ENGINE V750 IE 4.13.6. OIL PUMP REASSEMBLY • Assemble oil pump and reposition on block according to the two centering dowels. • Lock Allen screws to the prescribed torque and make sure the draw shaft revolves freely. 4 - 101...

  • Page 149: Oil Pressure Adjustment Valve Disassembly

    ENGINE V750 IE 4.13.7. OIL PRESSURE ADJUSTMENT VALVE DISASSEMBLY • Use appropriate spanner to unscrew adjustment valve fitted to threaded hole of block. 4 - 102...

  • Page 150: Oil Pressure Adjustment Valve Assembly

    ENGINE V750 IE 4.13.8. OIL PRESSURE ADJUSTMENT VALVE ASSEMBLY • Insert valve and spring and use dynamometric spanner to tighten the screw covered with thread locking paste to prescribed torque. 4 - 103...

  • Page 151: Oil Transmitter Reassembly

    ENGINE V750 IE 4.13.9. OIL TRANSMITTER REASSEMBLY • Insert oil sensor transmitter telltale on bushing and tighten to torque. 4 - 104...

  • Page 152: Tightening Torques

    ENGINE V750 IE 4.13.10. TIGHTENING TORQUES CRANKCASE AND COVERS Cylinder heads-barrels to crankcase fixing nut (M10) 40÷42 Nm Cylinder heads-barrels to crankcase fixing nut (M8) 28÷30 Nm Crankcases joining nuts (M8) 22÷25 Nm Crankcases joining nuts (M10) 40÷42 Nm Timing cover fixing screws...
  • Page 153 Moto Guzzi S.p.a. Via E.V. Parodi, 57 23826 Mandello del Lario (LECCO) Italy Tel. +39 0341 709111 Fax +39 0341 709220 www.motoguzzi.it www.servicemotoguzzi.com...

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