Moto Guzzi Daytona 1100 sport User Manual

The contents of this Manual is not binding and Moto Guzzi reserves the right to make alterations, if and when required, of components, accessories, tooling, etc. which are deemed expendient for the purpose of improvement or, for any technical-commercial requirement, or in order to comply with law provision in the different countries, without however undertaking to promptly up-date this Manual

Der Inhalt dieses Handbuchs ist unverbindlich. Moto Guzzi behält sich daher das Recht vor, Änderungen an Teilen, Zubehörteilen, Ausrüstungen usw. anzubringen, falls sich diese als notwendig erweisen sollten, um Verbesserungen auszuführen, technischen bzw. verkaufstechnischen Ansprüchen nachzukommen order um die Kriterien der Gesetzgebungen der einzelnen Länder zu erfüllen, ohne daß das Handbuch umgehend überarbeitet werden muß.

De inhoud van dit handboek is niet bindend en de firma GUZZI behoudt zich dan ook het recht voor, indien dit nodig mocht zijn, om door haar wenselijk geachte wijzigingen aan onderdelen, accessoires, hulpstukken e.d. aan te brengen teneinde naar verbetering van de producten te streven of naar aanleiding van welke noodzaak van technische of commerciële aard dan ook of met het oog op aanpassing aan de wettelijke eisen van de verschillende landen zonder echter verplicht te zijn dit handboek tijdig te updaten.

MOTO GUZZI S.p.A.

TECHNICAL PUBBLICATIONS / TECHNISCHE VERÖFFENTLICHUNGEN / TECHNISCHE UITGAVEN

Cod. 37 92 01 05

Printed in Italy - D.E.Ca. - Ravenna 1000 K - 05/95

INTRODUCTION

Purpose of this manual is to give the necessary instructions for overhauling and carrying out repairs in a rational way. All data herein contained are meant to give a general knowledge of the main checking operations to be done when overhauling

the different component groups. To this end, the manual contains many illustrations, drawings, diagrams, and tables to assist you in the stripping, checking,

and assembling operations. This manual will also be a guidance for anybody who wishes to familiarize with the manufacturing characteristics of the various

component parts of this model. The knowledge of these will be an essential factor for performing a good job.

EINFÜHRUNG

Dieses Handbuch soll die notwendigen Anlagen zur Durchführung von Überholungen und Reparaturen vermitteln. Die im Handbuch enthaltenen Daten geben auch einen allgemeinen Überblick darüber, welche Kontrollen beim Überholen

der einzelnen Baugruppen durchzuführen sind. Bilder, Zeichnungen und Diagramme; die für den Abbau, Kontrolle und Montage erforderlich sind, vervollstuandigen die

Angaben. Dieses Handbuch ist ebenso ein Leitfaden für den Kunden, die die Herstellungsdaten und Toleranzen der einzelnen Teile

wissen möchte. Für das Werkstattpersonal ist die Kenntnis dieser Daten eine Voraußetzung zur Durchfuuhrung sauberer Arbeiten.

VOORWOORD

Het doel van dit handboek is de nodige aanwijzingen te verstrekken om revisies en reparaties op rationele wijze uit te kunnen voeren. De opgenomen gegevens dienen om een algemeen inzicht te krijgen in de belangrijkste controles die tijdens de revisie van

de diverse onderdelen verricht moeten worden. Om de diverse onderdelen makkelijker te kunnen demonteren, controleren en monteren zijn de nodige afbeeldingen,

tekeningen en schema’s in dit handboek opgenomen. Dit handboek dient ook als leidraad voor diegenen die de constructieonderdelen van de motorfiets die in dit handboek aan

de orde komt willen leren kennen: kennis van deze onderdelen door het personeel dat met de reparaties belast is, is een essentiële factor voor de juiste uitvoering van de reparatiewerkzaamheden.

IMPORTANT

The text is supplemented with schematic illustrations for quick reference and better understanding of the subjects concerned. This manual contains some special remarks:

Accident prevention rules for the mechanic and for the personnel working nearby. Possibility of damaging the motorcycle and/or its components. Additional information concerning the job being carried out.

WICHTIG

Zum schnelleren Verständnis wurden die verschiedenen Paragraphen durch Abbildungen vervollständigt, die das behandelte Argument in der Vordergrund stellen. Dieses Handbuch enthält Informationen von besonderer Bedeutung:

Unfallverhütungsnormen für die am Motorrad arbeitende und die in der Nähe arbeitenden Personen. Es besteht die Möglichkeit das Motorrad und/oder seine Bestandteile zu beschädigen. Weitere Informationen für den laufenden Arbeitsvorgang.

BELANGRIJK

Om een snel begrip van de tekst te krijgen staan er schematische illustraties bij de diverse paragrafen die het onderwerp dat daarin behandeld wordt laten zien. In dit handboek zijn ter informatie opmerkingen opgenomen die een bijzondere betekenis hebben.

Veiligheidsvoorschriften voor degene die aan de motor werkt of die daar in de buurt van werkt. De mogelijkheid bestaat dat de motorfiets en/of de onderdelen ervan beschadigd worden. Nadere informatie over de handeling die op dat moment beschreven wordt.

NOTE The terms “right” and “left” in the text are to be considered as seen by the rider astride the machine.

ANM. In der Beschreibung erwähntes “Links” oder “Rechts” bedeuten immer in Fahrtrichtung gesehen.

OPMERKING Met “rechts” of “links” wordt de kant bedoeld vanaf de berijdersplaats gezien.

INDEX

1 IDENTIFICATION DATA ............................................................................................................... 6

1.1 Spare Parts .................................................................................................................................... 6

2 GENERAL FEATURES ................................................................................................................. 7

3 INSTRUMENTS AND CONTROLS ............................................................................................... 11

3.1 Control panel ................................................................................................................................. 11

3.2 Light switches ................................................................................................................................ 12

3.2.1 Switch, hazard warning lights ........................................................................................................ 12

3.3 Horn Button, Headlamp Flasher and direction indicators .............................................................. 12

3.4 «Choke» control............................................................................................................................. 12

3.5 Clutch lever .................................................................................................................................... 13

3.6 Starter Button and Engine Stop Switch ......................................................................................... 13

3.7 Throttle twist grip ........................................................................................................................... 13

3.8 Brake lever, front brake ................................................................................................................. 13

3.9 Brake pedal for rear brake ............................................................................................................. 13

3.10 Gearbox control pedal ................................................................................................................... 13

3.11 Fuel filler cap ................................................................................................................................. 14

3.12 Fuel tap .......................................................................................................................................... 14

3.13 Electric fuel cock ............................................................................................................................ 14

3.14 Fuse box ........................................................................................................................................ 15

3.15 Steering damper ............................................................................................................................ 15

3.16 Documents and objects holder ...................................................................................................... 16

3.17 Helmet holder ................................................................................................................................ 16

3.18 Motorbike lateral supporting arm ................................................................................................... 16

3.18.1 Side stand for motorcycle support with safety switch .................................................................... 17

3.19 Driver seat removal (DAYTONA RS and SPORT 1100 I) ............................................................. 17

3.20 Removing the saddle (V10 CENTAURO) ...................................................................................... 17

3.21 Passenger holding belt (V10 CENTAURO) ................................................................................... 18

4 LUBRICATION .............................................................................................................................. 19

4.1 Engine lubrication .......................................................................................................................... 19

4.2 Changing the filter cartridge and cleaning the mesh filter.............................................................. 19

4.3 Gearbox lubrication........................................................................................................................ 20

4.4 Rear transmission box lubrication.................................................................................................. 20

4.5 Greasing the driving shaft .............................................................................................................. 21

4.6 Front fork oil change ...................................................................................................................... 21

4.7 Greasing ........................................................................................................................................ 21

5 MAINTENANCE AND ADJUSTMENTS ....................................................................................... 22

5.1 Adjusting the clutch lever ............................................................................................................... 22

5.2 Adjusting the front brake lever ....................................................................................................... 22

5.3 Rear brake pedal adjustment......................................................................................................... 23

5.4 Adjusting the steering ................................................................................................................... 23

5.5 Adjustment of telescopic fork ......................................................................................................... 24

5.6 Rear suspension adjustment ......................................................................................................... 24

5.7 Changing the air filter..................................................................................................................... 26

5.7.1 Changing the air filter (V10 CENTAURO)..................................................................................... 27

5.8 Tappet clearance checking ............................................................................................................ 28

5.8.1 Timing belts (DAYTONA RS and V10 CENTAURO) ..................................................................... 28

5.9 Adjusting the headlight beam ........................................................................................................ 28

5.10 Cleaning the windscreen ............................................................................................................... 29

5.11 Motor washing rules....................................................................................................................... 29

6 SERVICE SCHEDULE .................................................................................................................. 30

7 TORQUE WRENCH SETTINGS ................................................................................................... 31

7.1 SPORT 1100 I ............................................................................................................................... 31

7.2 DAYTONA V10 CENTAURO ......................................................................................................... 32

8 SPECIFIC EQUIPMENT ................................................................................................................ 34

8.1 Specific equipment (DAYTONA RS and V10 CENTAURO) .......................................................... 36

9 REMOVING THE PROPULSOR UNIT FROM THE FRAME ........................................................ 38

9.1 V10 CENTAURO ........................................................................................................................... 39

9.2 SPORT 1100 I AND DAYTONA RS .............................................................................................. 40

10 ENGINE UNIT ................................................................................................................................ 42

10.1 Dismantling the engine assembly .................................................................................................. 42

10.1.1 Engine reassembly ........................................................................................................................ 50

10.1.2 Timing system phase-setting check ................................................................................................ 54

10.2 Checks ........................................................................................................................................... 55

11 ENGINE UNIT (DAYTONA RS AND V10 CENTAURO) ............................................................... 70

11.1 Engine dismantling ........................................................................................................................ 70

11.2 Engine reassembly ........................................................................................................................ 78

11.3 Engine timing ................................................................................................................................. 82

11.4 Checks ........................................................................................................................................... 87

12 WEBER INJECTION-IGNITION SYSTEM .................................................................................... 102

12.1 System components ...................................................................................................................... 102

12.2 Operation phases .......................................................................................................................... 102

12.3 Fuel circuit ..................................................................................................................................... 105

12.4 Air circuit ........................................................................................................................................ 106

12.5 Electric circuit ................................................................................................................................. 107

12.6 Calibration rules for carburation and regulation of the engine ....................................................... 111

12.7 TRIMMER operation on the electronic control unit type IAW 16M for CO regulation .................... 112

12.8 Starter lever adjustment................................................................................................................. 113

12.9 Adjustment of the starter RPM....................................................................................................... 113

12.10 Induction system control ................................................................................................................ 113

12.11 Use of the check lamp for the defects detection............................................................................ 114

12.12 Reset procedure for the electronic control unit IAW 16M .............................................................. 118

12.13 Spark plugs.................................................................................................................................... 118

12.14 Evaporative emission control system ............................................................................................ 119

13 CLUTCH ........................................................................................................................................ 122

14 GEARBOX..................................................................................................................................... 123

14.1 Gearbox lubrication........................................................................................................................ 124

14.2 Disassembly .................................................................................................................................. 124

14.3 Reassembly ................................................................................................................................... 129

15 REAR DRIVE................................................................................................................................. 131

15.1 Rear drive box lubrication .............................................................................................................. 132

15.2 Drive box disassembly ................................................................................................................... 132

15.3 Reassembly ................................................................................................................................... 134

15.4 Transmission shaft......................................................................................................................... 136

16 FRAME .......................................................................................................................................... 137

17 FRONT FORK ............................................................................................................................... 142

17.1 Change the fork oil......................................................................................................................... 142

17.2 Disassemble fork stem .................................................................................................................. 142

17.3 Removal of the screwed cap ......................................................................................................... 142

17.4 Oil draining..................................................................................................................................... 144

17.5 Cartridge disassembly ................................................................................................................... 144

17.6 Oil refilling ...................................................................................................................................... 145

17.7 Substituting the oil retainer bushing............................................................................................... 146

18 REAR SUSPENSION .................................................................................................................... 150

19 WHEELS ....................................................................................................................................... 152

19.1 Front wheel .................................................................................................................................... 152

19.2 Rear wheel..................................................................................................................................... 153

19.3 Tyres .............................................................................................................................................. 154

20 BRAKE SYSTEM .......................................................................................................................... 155

20.1 Checking brake pads wear ............................................................................................................ 157

20.2 Checking the brake fluid in the master cylinder reservoir .............................................................. 157

20.3 Checking brake disks..................................................................................................................... 158

20.4 Air bleeding from braking circuit .................................................................................................... 161

21 ELECTRICAL EQUIPMENT.......................................................................................................... 163

21.1 Battery ........................................................................................................................................... 163

21.2 Alternator and voltage controller....... ............................................................................................. 164

21.3 Starter motor .................................................................................................................................. 166

21.4 Lighting equipment ........................................................................................................................ 167

21.4.1 Replacing bulbs (DAYTONA RS and SPORT 1100 I) ................................................................... 167

21.4.2 Replacing bulbs (V10 VENTAURO) .............................................................................................. 168

21.5 Key to wiring diagram (DAYTONA RS and SPORT 1100 I) .......................................................... 170

21.6 Key to wiring diagram (V10 VENTAURO) ..................................................................................... 171

1 IDENTIFICATION DATA

(Fig. 01-01 / 01-02 / 01-03)

Every motorcycle is stamped with identification numbers on the tubular frame and on the crankcase. The frame number is written in the motorcycle logbook and is the vehicle’s legal identification.

V10 CENTAURO

1.1 SPARE PARTS Only «Original MOTO GUZZI Spare Parts» should be used.

The use of non-original parts invalidates the warranty.

01-02 01-03

DAYTONA RS / SPORT 1100 I

01-01

2 GENERAL FEATURES

ENGINE (SPORT 1100 I)

4-stroke, twin cylinder

Cylinder configuration: .......................................................................................................................90° V-twin

Bore:......................................................................................................................................................... 92mm

Stroke:..................................................................................................................................................... 80 mm

Displacement: ....................................................................................................................................... 1064 cc

Compression ratio: ................................................................................................................................... 10,5:1

Max. torque: ........................................................................................................ 97 Nm (9,9 kgm) at 6000 rpm

Max. power: ............................................................................................................66 KW (90 CV) at 7800 rpm

ENGINE (V10 CENTAURO AND DAYTONA RS) NOTE: The data in parenthesis [ ] apply to model DAYTONA RS only.

4-stroke, twin cylinder

Cylinder configuration: .......................................................................................................................90° V-twin

Bore:......................................................................................................................................................... 90mm

Stroke:..................................................................................................................................................... 78 mm

Displacement: ......................................................................................................................................... 992 cc

Compression ratio: ................................................................................................................................... 10,5:1

Max. torque: ............................................................................................. 88 Nm (9,0 kgm) at 5800 [7800] rpm

Max. power:......................................................... 70 KW (95 CV) at 8200 rpm [ 75 KW (102 CV) at 8400 rpm]

VALVE GEAR (SPORT 1100 I)

With rods and rockers and 2 valves per cylinder. One camshaft in the crankcase driven by duplex chain with automatic chain tensioner. The timing data (referring to the 1 mm lift of the tappets) are as follows:

Intake:

open 22° before TDC close 54° after BDC

Exhaust:

open 52° before BDC close 24° after TDC

Functioning clearance with a cold engine:

intake valves 0.10 mm exhaust valves 0.15 mm

VALVE GEAR (V10 CENTAURO and Mod. DAYTONA RS with specifications for USA, SWITZERLAND and SINGAPORE)

Overhead camshaft with 4 valves per cylinder. Straight-tooth gear control, in light alloy and positive drive belt. The timing data (referring to the 1 mm lift of the tappets) are as follows:

Intake:

open 22°30' before TDC close 57°30' after BDC

Exhaust:

open 49°30' before BDC close 12°30' after TDC

Functioning clearance with a cold engine:

intake valves 0.10 mm exhaust valves 0.15 mm

VALVE GEAR (DAYTONA RS - Model with specifications for USA, SWITZERLAND and SINGAPORE excluded)

Overhead camshaft with 4 valves per cylinder. Straight-tooth gear control, in light alloy and positive drive belt. The timing data (referring to the 1 mm lift of the tappets) are as follows:

Intake:

open 22°30' before TDC close 69°30' after BDC

Exhaust:

open 63°30' before BDC close 28°30' after TDC

Functioning clearance with a cold engine:

intake valves 0.10 mm exhaust valves 0.15 mm

Lubrication NOTE: The data in parenthesis [ ] apply to models DAYTONA RS and V10 CENTAURO.

Pressure fed by gear pump. Oil filters: wire mesh inside sump and replaceable cartridge filter outside sump. Normal lubrication pressure 3.8÷4.2 [5] kg/cm2, pressure valve, thermostat and cooler. Low oil pressure sensor (electrical) on crankcase.

GENERATOR / ALTERNATOR

On front of crankshaft (14V - 25A).

IGNITION

“WEBER MARELLI” electronic digital induced discharge, with high-efficiency coil. Spark plugs:

SPORT 1100I: NGK BPR 6 ES DAYTONA RS

V10 CENTAURO

STARTING

Electric starter (12V-1,2 kW) with solenoid engagement. Ring gear bolted on flywheel. Starter button (START) « » on right of handlebars.

TRANSMISSION DATA Clutch

Twin driven plates, dry type, on flywheel. Hand controlled by lever on left of handlebars.

NGK DR9 EA

}

Primary drive

By gears, ratio: 1 to 1.3529 (tooth ratio 17/23). By gears, ratio: 1 to 1.235 (tooth ratio 17/21). (Switzerland version only for model V10 CENTAURO)

GEARBOX

5-speed, with constantly meshed gears with front dog clutch. Incorporated cush drive. Pedal operated on the left side of the motorcycle.

NOTE: The SPORT 1100 I and DAYTONA RS models up to gearbox No. CF011499 and CL011199 have been provided with straight teeth; from the gearbox No. CF11400 and CL011200 they have been provided with helical teeth. The V10 CENTAURO model has a gearbox provided with helical tooth gears.

Gear ratios (DAYTONA RS and SPORT 1100 I):

Low gear = 1 to 1,8125 (tooth ratio 16/29) 2nd gear = 1 to 1,2500 (tooth ratio 20/25) 3rd gear = 1 to 1 (tooth ratio 23/23) 4th gear = 1 to 0,8333 (tooth ratio 24/20) 5th gear = 1 to 0,7308 (tooth ratio 26/19)

Gear ratios (V10 CENTAURO):

Low gear = 1 to 2 (tooth ratio 14/28) 2nd gear = 1 to 1,3158 (tooth ratio 19/25) 3rd gear = 1 to 1 (tooth ratio 23/23) 4th gear = 1 to 0,8462 (tooth ratio 26/22) 5th gear = 1 to 0,7692 (tooth ratio 26/20)

Gear ratios (V10 CENTAURO Switzerland version):

Low gear = 1 to 2 (tooth ratio 14/28) 2nd gear = 1 to 1,3889 (tooth ratio 18/25) 3rd gear = 1 to 1,0476 (tooth ratio 21/22) 4th gear = 1 to 0,8696 (tooth ratio 23/20) 5th gear = 1 to 0,7500 (tooth ratio 28/21)

Secondary transmission

Shaft with universal joint and gears. Ratio: 1:4,125 (tooth ratio 8/33)

Overall gear ratios (Engine-wheel) (DAYTONA RS and SPORT 1100 I):

Low gear = 1 to 10,1153 2nd gear = 1 to 6,9761 3rd gear = 1 to 5,5809 4th gear = 1 to 4,6507 5th gear = 1 to 4,0783

Overall gear ratios (Engine-wheel) (V10 CENTAURO): Overall gear ratios (Engine-wheel)

(V10 CENTAURO) Switzerland version:

Low gear = 1 to 11,1618 Low gear = 1 to 10,1912 2nd gear = 1 to 7,3433 2nd gear = 1 to 7,0772 3rd gear = 1 to 5,5809 3rd gear = 1 to 5,3382 4th gear = 1 to 4,7223 4th gear = 1 to 4,4309 5th gear = 1 to 4,2930 5th gear = 1 to 3,8217

FRAME

Rectangular section single-beam in NiCrMo steel. Semisupporting engine base.

SUSPENSIONS

Front: White Power upside-down hydraulic telescopic fork with individually adjustable rebound and compression; Rear: steel swing arm with oval cross section. Single shock absorber White Power with separate adjustment of spring preload and of hydraulic rebound and compression damping.

WHEELS

Light alloy castings with 3 hollow spokes (rear wheel with cush drive unit). Rim sizes: – front: 3,50x17 MT H2 – rear: 4,50x17 MT H2

TYRES NOTE: The data in parenthesis [ ] apply to models DAYTONA RS and V10 CENTAURO.

– front: 120/70 ZR 17 – rear: 160/70 ZR 17 [160/60 ZR 17] Type: Tubeless

BRAKES

Front: two Brembo drilled semi-floating disc brakes in stainless steel for SPORT 1100 and V10 CENTAURO; [two Brembo drilled floating discs, Racing type for DAYTONA RS] with fixed 4 differential piston calipers. Adjustable manual control lever on the right side of the handle-bar; – Ø disc 320 mm; – Ø brake cylinder 34/30 mm; – Ø master cylinder 16 mm. Rear: stainless steel fixed disc brake with fixed double braking cylinder caliper. Brake pedal on centre-right of motorbike; – Ø disc 282 mm; – Ø brake cylinder 32 mm; – Ø master cylinder 11 mm.

DIMENSIONS AND WEIGHT (SPORT 1100 I AND DAYTONA RS) NOTE: The data in parenthesis [ ] apply to models DAYTONA RS.

Wheelbase .................................................m 1,475

Overall length .............................................m 2,125

Overall width .............................................. m 0,720

Height......................................................... m 1,125

Ground clearance...........................m 0,160 [0,150]

Weight (dry)......................................... kg 221 [223]

DIMENSIONS AND WEIGHT (V10 CENTAURO)

Wheelbase .................................................m 1,475

Overall length .............................................m 2,180

Overall width .............................................. m 0,780

Height......................................................... m 1,094

Ground clearance.......................................m 0,154

Driver’s seat heigt ...................................... m 0,820

Weight (dry).................................................. kg 232

PERFORMANCE

Max. speed with one rider: 230 km/h for SPORT 1100 I (240 km/h for DAYTONA RS and 218 km/ h for V10 CENTAURO). Fuel consumption: 4,5 lt/100 km (CUNA).

REFUELINGS (DAYTONA RS AND SPORT 1100 I)

Description Quantity Recommended products

Fuel tank 19 l Supergrade petrol (97 NO-RM/min.) (reserve 3 l about) about Unleaded Petrol (95 NO-RM/min.)

Crankcase sump 3,500 l «Agip 4T Super Racing SAE 20W50» oil Gearbox 0,750 l «Agip Rotra MP SAE 80 W/90» oil Rear drive box 0,250

(crown wheel and pinion lubrication) 0,230 «Agip Rotra MP SAE 80 W/90» oil

Front fork (each leg) 0,400 «WP suspension-REZ 71» oil (SAE 5) Braking system (front and rear) — «Agip Brake Fluid - DOT 4» fluid

REFUELINGS (V10 CENTAURO)

Description Quantity Recommended products

of which

0,020 «Agip Rocol ASO/R» oil or «Molykote type A»

Fuel tank 18 l Supergrade petrol (97 NO-RM/min.) (reserve 5 l about) about Unleaded Petrol (95 NO-RM/min.)

Crankcase sump 3,500 l «Agip 4T Super Racing SAE 20W50» oil Gearbox 0,750 l «Agip Rotra MP SAE 80 W/90» oil Rear drive box 0,250

(crown wheel and pinion lubrication) 0,230 «Agip Rotra MP SAE 80 W/90» oil

Front fork (each leg) 0,400 «WP suspension-REZ 71» oil (SAE 5) Braking system (front and rear) — «Agip Brake Fluid - DOT 4» fluid

of which

0,020 «Agip Rocol ASO/R» oil or «Molykote type A»

3 INSTRUMENTS AND CONTROLS

3.1 CONTROL PANEL (Fig. 03-01)

1 Key switch for devices and steering lock.

Position OFF « Position ON « » vehicle ready to be started. All circuits are on. Key not removable. Position LOCK « » steering locked. Engine off, no contact, key removable. Position P « » steering locked. Engine off; with switch «A» of Fig. 03-01 in position « » the parking light is

on. Key removable.

» vehicle stationary. Key removable (no contact).

DAYTONA RS / SPORT 1100 I

In order to use the steering lock mechanism, proceed as follows:

■ Turn the handlebars to the left.

■ Press the key downwards and release it, then turn it in an anticlockwise direction to the LOCK « » or P « »

position.

WARNING: Never turn the key to position LOCK « » or P « » when the engine is running. 2 Odometer, tachometer.

3 Rev counter. 4 Pilot light (green) «Neutral». Lights up when the gearbox is in neutral. 5 Pilot light (red) for generator current output. Should go out when the engine reaches a certain number of revs. 6 Petrol tank reserve pilot light (orange). 7 Pilot light (green) for flashing indicators. 8 Oil pressure pilot light (red). Goes out when the oil pressure is sufficient to ensure engine lubrication. 9 Pilot light (blue) for main beam. 10 Partial rev counter zeroing.

03-01 03-01

V10 CENTAURO

3.2 LIGHT SWITCHES (Fig. 03-02 / 03-03)

Are fitted to the sides of the handle-bars.

Switch «A»

■ Position « » lights off.

■ Position « » parking lights on.

■ Position « » twin-filament headlamp on.

Switch «B»

With switch «A» in position « ».

■ Position « » dipped beam.

■ Position « » main beam.

3.2.1 SWITCH, HAZARD WARNING LIGHTS («H» DI Fig. 03-02) (DAYTONA RS /SPORT 1100 I)

It is installed on the left hand side of the fairing and turns on both flashers at the same time.

DAYTONA RS / SPORT 1100 I

03-02

V10 CENTAURO

03-02

DAYTONA RS / SPORT 1100 I

03-03

V10 CENTAURO

3.3 HORN BUTTON, HEADLAMP FLASHER AND DIRECTION INDICATORS (Fig. 03-02)

These are mounted on the left handlebar:

Push-button E « » sounds the electric horn when pressed. Push-button C « » flashing light control. Push-button «D» (turn).

■ Position « » for right turn signals control.

■ Position « » for left turn signals control.

■ Press the switch to disconnect flashers.

3.4 «CHOKE» CONTROL («F» IN Fig. 03-02)

The «CHOKE» is on the left handlebar and is used for cold starts.

■ Position «1» CHOKE on; starting position.

■ Position «2» CHOKE off; engine running.

03-03

3.5 CLUTCH LEVER («G» IN Fig. 03-02)

This is on the left handlebar and is only to be used when starting or changing gear.

3.6 STARTER BUTTON AND ENGINE STOP SWITCH (Fig. 03-03)

These are mounted on the right handlebar. With the key «1» in Fig. 03-01 in position ON « », the vehicle is ready for starting. To start the engine:

■ check that switch «B» is in position (run);

■ pull the clutch lever in to disengage the clutch fully;

■ if the engine is cold, put the «CHOKE» control «F» in the starting position «1» (see Fig. 03-02).

■ press the starter button A «» (start).

To stop the engine in case of emergency:

■ turn the switch «B» to position (off). Once the engine has stopped, turn the key switch Fig. 03-01 in position OFF « » remove the key from the switch.

NOTE: Before start, put switch «B» in (RUN) position.

3.7 THROTTLE TWIST GRIP («C» in Fig. 03-03)

The throttle control is on the right handlebar; turning the twist-grip towards the rider opens the throttle, turning it away from the rider closes it.

3.8 BRAKE LEVER, FRONT BRAKE («D» in Fig. 03-03)

This is on the right handlebar and controls the master cylinder of the front brake.

3.9 BRAKE PEDAL FOR REAR BRAKE («A» in Fig. 03-04)

This is centrally located on the right side of the vehicle and is linked to the rear brake master cylinder by a tierod.

3.10 GEARBOX CONTROL PEDAL (Fig. 03-05)

This is situated on the left of the motorcycle:

■ 1st gear: push pedal down;

■ 2nd, 3rd, 4th, 5th gears: pull pedal up;

■ neutral: between 1st and 2nd gears.

NOTE: Before changing gear disengage the clutch fully.

DAYTONA RS / SPORT 1100 I

03-04

V10 CENTAURO

03-04

DAYTONA RS / SPORT 1100 I

03-05

V10 CENTAURO

03-05

3.11 FUEL FILLER CAP (Fig. 03-06)

To open the filler cap, turn the key clockwise.

NOTE: Fuel spillage caused during refuelling should be cleaned immediately to prevent damage to

the fuel tank paintwork.

DAYTONA RS / SPORT 1100 I

3.12 FUEL TAP (DAYTONA RS / SPORT 1100 I) (Fig. 03-07)

The motor vehicle is fitted with a motor-driven pump that regulates the fuel flow from the tank to the engine. If the petrol tank has to be removed, before disconnecting the pipes the tap «A» on the bottom of the tank on the rear left-hand side must be tightly closed. Approximately every 10000 km, clean the net filter on the tap.

3.13 ELECTRIC FUEL COCK (V10 CENTAURO) (Fig. 03-08)

The vehicle is provided with an electric cock «A» fitted on the left side under the tank, which operates automatically, cutting off fuel flow to the throttle unit when the engine is not running. It comes into play when the key of the change-over switch «1» on Fig. 03-01 is in its ON position « Should the cock not be working properly, first check the condition of the fuse «3» on Fig. 03-09. Approximately every 10000 km, clean the net filter on the tap.

03-06

V10 CENTAURO

03-06

».

DAYTONA RS / SPORT 1100 I

03-07

V10 CENTAURO

03-08

3.14 FUSE BOX («A» IN Fig. 03-09)

Situated on the rear right-hand side of the motorbike; remove the passenger seat to access to it (see Par. 3.20). In the V10 CENTAURO the terminal board is located on the rear left side of the motorcycle; to reach it, remove the saddle. The fuse box has 6 «15 Amp» fuses; their functions are indicated by the decal on the cover. Before changing a burnt fuse, trace and repair the cause of the trouble.

Fuse «1»: fuel pump, coils, electric injectors. Fuse «2»: electronic box. Fuse «3»: emergency flashers [electric cock in V10 CENTAURO model]. Fuse «4»: driving beam, traffic beam, passing light, horns, front lever stop light, rear pedal stop ligh, starting

motor.

Fuse «5»: tail light, dashboard lights, instruments lighting. Fuse «6»: blinkers intermittence.

DAYTONA RS / SPORT 1100 I

V10 CENTAURO

3.15 STEERING DAMPER (Fig. 03-10)

This is fitted on the front part of the motorbike between the frame and the steering base. To increase or reduce the braking effect, screw or unscrew the knob «A».

03-09

DAYTONA RS / SPORT 1100 I

03-10

V10 CENTAURO

03-10

3.16 DOCUMENTS AND OBJECTS HOLDER («A» Fig. 03-11)

It is located in the motorcycle rear side; to reach it, remove the passenger seat by releasing the lock «B» with the same key of the ignition switch. Model V10 CENTAURO: to reach it, you must remove the saddle (see «Removing the Saddle» on Par. 3.20).

DAYTONA RS / SPORT 1100 I

3.17 HELMET HOLDER (Fig. 03-12) The helmet can be left with the motorcycle, using the helmet holder with lock «A».

DANGER: Never leave the helmet in the holder when the motorcycle is running, as it may interfere

with the moving parts.

DAYTONA RS / SPORT 1100 I

03-11

03-12

V10 CENTAURO

03-11

03-12

3.18 MOTORBIKE LATERAL SUPPORTING

ARM («A» - Fig. 03-13) (VALID FOR ALL MODELS MANUFACTURED UNTIL 12/12/1997)

The motorbike is equipped with an arm that serves as a lateral support during parking; when the motorbike is moved to an upright position the lateral arm automatically returns to the rest position.

03-13

3.18.1 SIDE STAND FOR MOTORCYCLE

SUPPORT WITH SAFETY SWITCH (VALID FOR ALL MODELS MANUFACTURED AFTER JAN. 1 1998)

The motorcycle is equipped with a side stand that supports it during parking («A» - Fig. 03-14).

When the stand is in parking position (all out) the microswitch («B» - Fig. 03-14) operates a remote control switch that breaks the current delivery to the starting motor: in these conditions the motor cannot be started.

3.19 DRIVER SEAT REMOVAL (DAYTONA RS AND SPORT 1100 I - Fig. 03-15)

To remove the seat from the chassis use a 6 mm Allen wrench to unscrew, from both sides, the screw-pins «A» which can be reached through the holes «B» made on the tail side.

NOTE: It is not necessary to completely unscrew the screws, just loosen them as required to remove

the seat.

03-14

3.20 REMOVING THE SADDLE (V10 CENTAURO - Fig. 03-16)

To remove the saddle from the frame, you must: release the saddle using the key «A». To fasten the saddle, you must fit it into its seat on the fuel tank and then press down on its rear part.

03-15

03-16

3.21 PASSENGER HOLDING BELT

(V10 CENTAURO) (Fig. 03-17)

The motorcycle is equipped with a passenger holding belt originally located underneath the saddle. To use it proceed as follows:

■ Release the saddle from the frame (Fig. 03-16);

■ Dismantle the saddle-covering fairing (if

assembled);

■ Lift the belt and insert the saddle between it and

the frame;

■ Fasten the saddle back in place.

03-17

4 LUBRICATION

4.1 ENGINE LUBRICATION (Fig. 04-01) Checking the oil level

Check the crankcase oil level every 500 km; the oil should reach the «Max» mark of the dipstick «A». If the oil is below this level, top up with the recommended type and grade of oil.

The oil level check should be carried out after the engine has run for a few minutes: the dipstick plug «A» should be screwed fully home.

Oil change

The oil should be changed after the first 500÷1500 km and every 5000 km thereafter. Change the oil when the engine is warm. Allow the sump to drain fully before filling with new oil .

«A» Oil filler plug with dipstick Fig. 04-01. «B» Oil drain plug Fig. 04-02.

Oil required: about 3,5 litres of «Agip 4T Super Racing SAE 20W/50».

DAYTONA RS / SPORT 1100 I

4.2 CHANGING THE FILTER CARTRIDGE AND CLEANING THE MESH FILTER (Fig. 04-02)

After the first 500÷1500 km (first oil change) and then every 10,000 km (2 oil changes), replace the filter cartridge as follows:

■ unscrew the oil drain plug «B» and drain all oil out of the sump;

■ unscrew the cover «A» using the tool code 01929100;

■ unscrew the filter cartridge «C» using the same tool and replace it with an original cartridge.

When refitting cover «A», check its oil seal «D» and replace it if necessary. These operations are best carried out by an authorized dealer.

04-01

V10 CENTAURO

04-01

04-02

Washing the wire mesh filter (Fig. 04-03)

After the first 500÷1500 km, (first oil and filter cartridge change), and then every 30.000 km it is recommended to remove the oil sump from the engine block, remove the wire mesh filter «E» and wash everything in petrol; then blow the filter with a compressed air jet. Don’t forget to fit a new sump gasket when refitting the sump. These operations are best carried out by an authorized dealer.

4.3 GEARBOX LUBRICATION (Fig. 04-04) Checking the oil level

Check the oil level every 5000 km; the oil should just reach the level plug hole «B». If the oil is below this level top up with the recommended grade and type of oil.

Oil change

The gearbox oil should be changed every 10.000 km. Drain the oil when the gearbox is warm as the oil is more fluid and drains more easily. Allow the gearbox to drain fully before filling with new oil.

«A» Filler plug. «B» Level plug. «C» Drain plug.

Oil required: 0.750 litres of «Agip Rotra MP SAE 80W/90».

04-03

04-04

4.4 REAR TRANSMISSION BOX LUBRICATION

(Fig. 04-05)

Checking the oil level

Check the oil level every 5000 km; the oil should just reach the level plug hole «A». If the oil is below this level top up with the recommended grade and type of oil.

Oil change

The transmission box oil should be changed every

10.000 km. Drain the oil when the box is warm as the oil is more fluid and drains more easily. Allow the box to drain fully before filling with new oil.

«A» Level plug. «B» Filler plug. «C» Drain plug.

Oil required: 0.250 litres of which:

0.230 lt. is «Agip Rotra MP SAE 80W/90»;

0.020 lt. is «Agip Rocol ASO/R» or «Molykote type A».

04-05

4.5 GREASING THE DRIVING SHAFT (Fig. 04-06)

The vehicle has a driving shaft provided with greasers. The greasing operation of the 3 places shown in figure should be made every 2500 kms (every 1000 Km in case of continuous usage at high speed) or at least once a year if the number of kilometers is lower. Lubrication is recommended every time the motorbike is washed.

TYPES OF GREASE TO BE USED

■ AGIP GREASE 30

■ AGIP GR LP2

■ ESSO LADEX 2

■ MOBIL PLEX 48

■ SHELL RHODINA GRIS 2

■ SHELL SUPERGRIS EP 2

04-06

4.6 FRONT FORK OIL CHANGE

Change fork oil about every 15,000 km or at least once a year. Amount of oil required: about 0,400 litres cartridge oil «WP suspension - REZ 71 (SAE 5)».

NOTE: For further details on the oil replacement procedure, refer to the fork section in Chapter 17.

4.7 GREASING

To grease:

■ steering bearings;

■ swinging arm bearings;

■ control rod joints;

■ side stand fittings;

■ Articulated joints and needle bearing - rear driving box.

Use: «Agip Grease 30».

5 MAINTENANCE AND ADJUSTMENTS

5.1 ADJUSTING THE CLUTCH LEVER (Fig. 05-01)

There should be 3÷4 mm of free play at the lever; turn the adjuster screw «A» to obtain the desired play Play can also be adjusted on the cable adjuster «B» located on the right side of the gearbox. First loosen the lock nut «C» and then adjust. The distance of the handle lever can be adjusted by turning ring nut «D» which has 4 positions.

DAYTONA RS / SPORT 1100 I

V10 CENTAURO

5.2 ADJUSTING THE FRONT BRAKE LEVER (Fig. 05-02) The distance of the handle lever can be adjusted by turning ring nut «A» which has 4 positions.

05-01

DAYTONA RS / SPORT 1100 I

05-02

V10 CENTAURO

05-02

5.3 REAR BRAKE PEDAL ADJUSTMENT (Fig. 05-03)

Check that brake pedal «A» has an idle stroke of approx. 5÷10 mm. before the end of rod «B» comes into contact with the brake pump master cylinder; otherwise alter the length of rod «B» by tightening or untightening it, after having loosened off lock nut «C». To change the position of the pedal «A», loosen the screw «D» and adjust the cam «E»; at the same time vary the length of the rod «B» until the correct clearance is obtained.

DAYTONA RS / SPORT 1100 I

5.4 ADJUSTING THE STEERING (Fig. 05-04)

To ensure safe riding, the steering should be adjusted in such a way as to allow free movement of the handlebars without any play.

• loosen the steering head fixing bolt «A»;

• undo the steering head nut «B»;

• turn the adjuster nut «C» to take up any play. When the play has been adjusted, tighten nut «B» and the steering head fixing bolt «A».

05-03 05-03

V10 CENTAURO

DAYTONA RS / SPORT 1100 I

05-04

V10 CENTAURO

05-04

5.5 ADJUSTMENT OF TELESCOPIC FORK (Fig. 05-05)

The motorbike is fitted with an hydraulic telescopic fork with separate adjustment of the rebound damping and compression damping. Hydraulic damping can be adjusted turning adjuster screws «A» and «B» with a screw driver. The left-hand adjuster screw «A» adjusts hydraulic rebound damping, the righ-hand screw «B» if for compression damping. Both adjuster screws have several settings (clicks); turning clockwise (+) you will get a stiffer damping, turning anticlockwise (–) will give a softer damping.

NOTE: Do not try to turn the adjusters screws further than their limit positions.

DAYTONA RS / SPORT 1100 I

5.6 REAR SUSPENSION ADJUSTMENT (Fig. 05-06 / 05-07 / 05-08 / 05-09) NOTE: The changes concerning the V10 CENTAURO model are shown in brackets [ ].

The motorcycle is equipped with “WHITE POWER” single shock absorbers with separate adjustment of the springs pre-loading and the rebound damping and compression damping. The shock absorber is calibrated in the factory to the following standard values: REBOUND: position 5 [1] (ring nut A) COMPRESSION: position 4 [1] (knob B) SPRING PRELOADING:14 mm [11 mm] Use the adjusting ring nut «A» shown in Fig. 05-07 to adjust the rebound damping. Access to the ring nut is obtained by removing the rider seat (see Par. 3.19 «REMOVAL OF RIDER SEAT») and the computer box «1» shown in Fig. 05-06.

05-05

V10 CENTAURO

05-05

DAYTONA RS / SPORT 1100 I

05-06

DAYTONA RS / SPORT 1100 I

05-07

In the V10 CENTAURO model, the adjustment ring nut«A» - Fig. 05-07 can be reached by removing the saddle (see Removing the saddle in Chapter 3.20) and moving the battery. According to needs and the load on the motorcycle, the damper can be set from position “1” (very soft) to position “11” (very hard). The hydraulic damper in compression can be set by turning adjusting knob «B» in Fig. 05-08 that has nr. 7 setting positions; from position “1” minimum damping, to position “7” maximum damping. To adjust the pre-loading of the spring, using the correct wrench, loosen off ringnut «C» and adjust ringnut «D»; tightening up increases the spring preloading (see Fig. 05-09). The spring preload, starting from a completely

released spring, is 10 to 18 mm. The released spring length is 165 mm.

NOTE: To avoid damaging the thread between the damper body and the ring nut «D», lubricated the

thread with «SVITOL», with oil or with grease.

WARNING In the model DAYTONA RS and SPORT 1100 I When refitting the electronic box, do not forget to reconnect the terminals of the ground wires «2» under the fastening screw «3» of the electronic box (see Fig. 05-06 and 05-07).

V10 CENTAURO

05-07

DAYTONA RS / SPORT 1100 I

05-08

05-09

V10 CENTAURO

05-08

5.7 CHANGING THE AIR FILTER (DAYTONA RS AND SPORT 1100 I - Fig. 05-10)

Check the air filter every 5000 km and clean by blowing with compressed air; change every 10.000 km. This filter is installed inside a proper housing over the motor unit. To reach it, remove the driver saddle, the body sides and the fuel tank (see SPECIFIC INSTRUCTIONS par. 9.2).

05-10

05-11

5.7.1 CHANGING THE AIR FILTER (V10 CENTAURO) (Fig. 05-12)

Check the air filter every 5000 km and clean by blowing with compressed air; change every 10.000 km. This filter is assembled in a special housing above the engine unit; to reach it, you must take off the saddle, the sides and the fuel tank (see SPECIFIC INSTRUCTIONS par. 9.1).

05-12

05-13

5.8 TAPPET CLEARANCE CHECKING (Fig. 05-14)

After the first 500÷1500 km, and then every 5000 km or when the valves are very noisy, check the clearance between the valves and the rockers. This check is done on a cold engine, with the piston at top dead center «T.D.C.» at the end of the compression stroke (valves fully closed). Remove the rocker cover and proceed as follows: 1 Loosen nut «A». 2 adjust screw «B» to set the following clearances, using a feeler gauge:

■ intake valve 0.10 mm;

■ exhaust valve 0.15 mm.

Use a suitable feeler gauge «C» to measure the clearance. Note that excessive clearance causes noise, whereas with insufficient clearance the valves do not close fully, causing:

■ compression loss;

■ engine overheating;

■ valve burning, etc.

5.8.1 TIMING BELTS (DAYTONA RS AND V10 CENTAURO)

Every 30,000 km replace the distribution timing belts.

SPORT 1100 I

5.9 ADJUSTING THE HEADLIGHT BEAM (Fig. 05-15)

The headlight beam should always be kept adjusted to the correct height to ensure good visibility and to avoid dazzling oncoming traffic. For vertical adjustment, turn screw «A», and move the light up or down as required. In the V10 CENTAURO model, the vertical orientation can be obtained by loosening the two screws «C» which fasten the headlight and manually moving it upward or downward until the required height is reached.

05-14

V10 CENTAURO / DAYTONA RS

05-14

DAYTONA RS / SPORT 1100 I

05-15

V10 CENTAURO

05-15

5.10 CLEANING THE WINDSCREEN

The windscreen can be cleaned using most of the soaps, cleaners, waxes and polishes commercially available for glass and plastic. The following precautions should be taken:

■ do not wash or polish the windscreen in direct or strong sunlight or when temperatures are high;

■ under no circumstances use solvents, lyes or similar products;

■ do not use abrasive substances, pumice, sand/emery paper, files, etc.;

■ wash all dust and dirt away before polishing. Small superficial scratches can be removed using a mild polish;

■ paint or sealing compound can be removed before harden by using diesel, isopropylic alcohol or butyl

cellosolvent (do not use methyl alcohol).

5.11 MOTOR WASHING RULES Preparations for washing

Before washing the vehicle, the following parts should be covered with a waterproof material: the rear part of the silencers, the clutch and brake levers and pedals, the throttle twist-grip, the left-hand light switch, the ignition key switch, the shaft with driving couplings and the electronic box.

NOTE: The electronic box is located under the seat. In the DAYTONA RS and SPORT 1100 models, the electronic unit is located under the driver saddle.

Washing

Avoid spraying water too much pressure on the instruments and the front and rear hubs.

WARNING: Do not clean the joints with high-pressure water or with solvents.

Drying

Remove the protective coverings. Thoroughly dry the vehicle. Test the brakes before using the vehicle. It is recommended to grease the shaft with driving couplings (see Fig. 04-06).

NOTE: To clean the painted parts of the engine unit (engine, gearbox, transmission box, etc.) the following products may be used: diesel oil, petrol or water-based neutral detergents for car cleaning. These products should be washed off immediately with water; do not use water at high temperatures or pressures.

(27000 mi.) (30000 mi.)

(24000 mi.)

(18000 mi.) (21000 mi.)

(12000 mi.) (15000 mi.)

1500 Km 5000 Km 10000 Km 15000 Km 20000 Km 25000 Km 30000 Km 35000 Km 40000 Km 45000 Km 50000Km

(1000 mi.) (3000 mi.) (6000 mi.) (9000 mi.)

MILEAGE COVERED

6 SERVICE SCHEDULE

ITEMS

Engine oil RR R R RR R R R R R

Oil filter cartridge RR RR R R

Wire gauze oil filter CC

Air filter CRC RCRCR CR

Fuel filter RRRRR

Ignition phase-setting A

Spark plugs AA R A RA R A R A R

Rocker clearance AA A A AA A A A A A

Distribution timing belts

(DAYTONA RS e V10 CENTAURO) AA AR A A

Carburation AA A A AA A A A A A

Nuts and bolts AA A A AA A A A A A

Fuel tank, tap filter and pipes AAAAA

Gearbox oil RA R A RA R A R A R

Rear drive box oil RA R A RA R A R A R

Shaft with drive joints ● AA AA R ❋ R A A R ❋ A R A R ❋ A

Wheel and steering bearings AA

•Grease every 2500 Km (every 1000 Km in case of continuous use at high speed) or at least once a year in case of less miles covered.

*In the event of mainly sporting use or regular high speed travel, replace every 15,000 km.

Front forks oil RR R

Starter motor and generator AA

Brake system fluid AA A R AA R A A R A

Brake pads AA A A AA A A A A A

A= Maintenance - Inspection - Adjustment - Possible replacement./ C = Cleaning./ R = Replacement.

Occasionally check the level of the electrolyte in the battery and lubricate the rear suspension joints of the controls and the flexible cables, every 500 km check the oil level in

the engine.

The engine oil, the front fork oil and the brake fluid must be changed at least once a year.

7 TORQUE WRENCH SETTINGS

7.1 SPORT 1100 I

DESCRIPTION Kgm

Nut and stud for cylinder-head tie rods (dia. 10x1.5) ............................................. 4÷4,2

Bolt, rocker pin securing......................................................................................... 0,6÷0,8

Spark plugs ............................................................................................................ 2÷3

Hollow screws securing pipes delivering oil to the heads (dia. 8x1.25) ................. 1,5÷1,8

Nut, gear to camshaft............................................................................................. 15

Screw, intake pipe.................................................................................................. 2

Connecting rod cap securing screws (dia.10x1) .................................................... 6,1÷6,6

Connecting rod cap securing screws CARRILLO ................................................. 8,5÷9,3

Screws securing flywheel to engine shaft (dia.8x1.25) - with Loctite medium compound .

Screws securing flywheel crown (dia.6x1) ............................................................. 1,5÷1,7

Nut locking the driving shaft pinion (diam. 25 x 1.5)

Nut locking alternator (dia.16x1.5) ......................................................................... 8

Nut locking secondary shaft ................................................................................... 16÷18

Cap for topping up oil in gearbox and transmission............................................... 3

Safety nut for secondary shaft ............................................................................... 7÷8

Nut locking bearing on bevel pinion ....................................................................... 18÷20

Screws securing crown to drilled pin...................................................................... 4÷4,2

Screw to fix. side stander support plate ................................................................. 7÷7,5

Front wheel spindle................................................................................................ 9÷10

Screw for rear wheel spindle (case side) ............................................................... 12

Fastening screws for front and rear brake discs (Ø8x1.25) - with Loctite 270...... 2,8÷3

4÷4,2

Standard values

Screws and nuts dia. 4 mm.................................................................................... 0,3÷0,35

Screws and nuts dia. 5x0.8 mm............................................................................. 0,6÷0,7

Screws and nuts dia. 6x1 mm................................................................................ 0,8÷1,2

Screws and nuts dia. 8x1.25 mm ........................................................................... 2,5÷3

Screws and nuts dia. 10x1.5 mm ........................................................................... 4,5÷5

Other tightening torques are indicated on the drawings of the suspension, front wheel, and rear wheel assemblies.

7.2 DAYTONA V10 CENTAURO

DESCRIPTION Kgm

Nut for cylinder-head tie rods (dia. 10x1.5)............................................................ 4,2÷4,5

Nut for frame securing screw stud (dia.8x1.25) ..................................................... 2,2÷2,3

Spark plugs ............................................................................................................ 1,5÷2

Hollow screws securing pipes delivering oil to the heads (dia. 10x1.5) ................. 2÷2,5

Head temperature sensor case (with Loctite 601) ................................................. 1÷1,2

Head temperature sensor ...................................................................................... 1÷1,2

Air temperature sensor securing screw ................................................................. 0,1

Connecting rod cap securing screws CARRILLO ................................................. 8,5÷9,3

Screws securing flywheel to engine shaft (dia.8x1.25) .......................................... 4÷4,2

Screws securing flywheel crown (dia.8x1.25) ........................................................ 3

Nut locking engine shaft pinion (dia.25x1.5) .......................................................... 11÷12

Nut locking alternator (dia.16x1.5) ......................................................................... 9÷9,5

Nut securing service shaft pulley (dia.16x1.5) ....................................................... 10÷12

Nut securing timing shaft pulley (dia.14x1.5) ......................................................... 6÷7

Nut securing oil pump gear (dia.8x1) - with Loctite 601......................................... 2÷2,2

Pressure control valve (dia.14x1.5) - with Loctite 601 ........................................... 6÷7

Nut locking secondary shaft................................................................................... 16÷18

Cap for topping up oil in gearbox and transmission............................................... 3

Cap for measuring oil level and discharge from gearbox and transmission .......... 2,5

Safety nut for secondary shaft ............................................................................... 7÷8

Nut locking bearing on bevel pinion ....................................................................... 18÷20

Screws securing crown to drilled pin...................................................................... 4÷4,2

Screw to fix. side stander support plate ................................................................. 7÷7,5

Screw for rear wheel spindle (case side) ............................................................... 12

Front wheel spindle................................................................................................ 9÷10

Fastening screws for front and rear brake discs (Ø8x1.25) - with Loctite 270...... 2,8÷3

Standard values

Screws and nuts dia. 4 mm.................................................................................... 0,3÷0,35

Screws and nuts dia. 5x0.8 mm............................................................................. 0,6÷0,7

Screws and nuts dia. 6x1 mm................................................................................ 0,8÷1,2

Screws and nuts dia. 8x1.25 mm........................................................................... 2,5÷3

Screws and nuts dia. 10x1.5 mm........................................................................... 4,5÷5

Other tightening torques are indicated on the drawings of the suspension assemblies.

8 SPECIFIC EQUIPMENT

40*

41*

39*

N. CODE No. DESCRIPTION

1 01 92 91 00 Cap demounting wrench on cup and filter 2 14 92 96 00 Gear box support 3 19 92 96 00 Setting dial for distribution and ignition phase check 4 17 94 75 60 Arrow for distribution and ignition phase check 5 12 91 36 00 Tool for flywheel side flange disassembly 6 12 91 18 01 Tool for locking flywheel and crown starter 7 10 90 72 00 Tool for valve assembly and disassembly 8 30 91 28 10 Tool for internal clutch body locking

9 30 90 65 10 Tool for clutch assembly 10 12 90 59 00 Tool for clutch shaft disassembly with components 11 14 92 71 00 Instrument to install the sealing ring on the flange, flywheel side 12 12 91 20 00 Tool for flywheel side flange assembly complete with casing on engine shaft 13 14 92 72 00 Tool for distribution cover sealing ring assembly 14 12 90 71 00 Tool for transmission shaft locking 15 14 92 87 00 Tool for pre-selector activation 16 14 90 54 00 Tool for transmission shaft locking nut 17 14 91 26 03 Appropriate wrench for shaft internal clutch body retaining ring nut 18 14 91 31 00 Estractor for needle bearings on main shaft box and on clutch shaft cover 19 14 92 85 00 Tool for extracting the clutch shaft internal bearins track 20 17 94 92 60 Extractor for bearings for clutch shaft on box and transmission shaft on cover 21 17 94 50 60 Extractor for needle external bearings track for transmission shaft on box and

external bearings track on casing 22 14 90 70 00 Extractor for ball bearings for main shaft on cover 23 12 90 69 00 Extractor for transmission box needle bearings ring 24 17 94 83 60 Extractor for needle internal bearings track on box holed pin 25 17 94 84 60 Tool for pressing the internal needle bearings track on the transmission box holed

pin 26 17 94 88 60 Punch for the bearing external track of the drive shaft sealing ring 27 17 94 54 60 Tool for positioning the internal bearings ring on the main shaft and on the clutch

shaft 28 14 92 86 00 Tool for positioning the internal bearing ring on the transmission shaft 29 14 92 89 00 Punch for pressing the clutch shaft bearings on the box, for the transmission shaft

cover, and for the transmission box rear sealing ring 30 14 92 91 00 Punch for pressing the transmission shaft external needle bearings ring on the box 31 14 92 88 00 Punch for pressing the main shaft needle bearings on the box and the clutch shaft

on the cover 32 17 92 90 00 Punch for pressing the ball bearings for the main shaft on the cover 33 14 92 94 00 Punch for pressing the sealing ring on the clutch shaft gear box 34 14 92 95 00 Punch for pressing the sealing ring on the transmission shaft cover 35 17 94 51 60 Punch for pressing the external bearing tracks on the casing 36 14 92 93 00 Tool for positioning the sliding sleeve fork control 37 01 92 93 00 Locking ring nut wrench for front wheel pin 38 00 95 00 55 Manometer for engine oil pressure and fuel pressure check for vehicles with

electronic injection systems

39* 19 92 71 00 Tool for installing seal ring on flange, flywheel side 40* 14 92 73 00 Tool for holding camshaft gear 41* 65 92 84 00 Hub for degree whell

NOTE: The details with asterisk (*) apply to model SPORT 1100 I only.

8.1 SPECIFIC EQUIPMENT (DAYTONA RS AND V10 CENTAURO)

N. CODE No. DESCRIPTION

1 30 92 72 00 Tool for rotating cam shaft 2 30 92 73 00 Tool for cam shaft pulley seal with 22 mm socket wrench inserted for pulley nut

locking

3 30 92 76 00 Tool for service shaft pulley seal and oil pump gear 4 30 94 86 00 Tool for distribution belt tensor 5 69 90 78 50 Test indicator 6 30 94 82 00 Head test indicator 7 30 94 83 00 Tool for extracting oil pump gear control, service shaft pulley and internal cam shaft

pulley gear

8 30 94 96 00 Setting dial hub 9 61 90 19 00 Plug socket wrench

10 30 90 84 00 Pin for socket wrench

9 EMOVING THE PROPULSOR UNIT FROM THE FRAME

9.1 V10 CENTAURO

To disassemble, proceed as follows:

• Remove the saddle from the frame using the wrench «A» - Fig. 09-01;

09-01

• Remove the body sides by loosening the screws «B» - Fig. 09-02 from both sides of the motorcycle;

• Remove the tail by loosening the 6 fastening screws «C» - Fig. 09-02;

• Disconnect the fuel pipe «D» - Fig. 09-03 from the pressure adjuster and the fuel pipe «E» - Fig. 09-04 from the left electric cock;

• Unscrew the tank rear fastening screw «1» - Fig. 09-04;

• Disconnect the fuel level indicator connector «F»

- Fig. 09-05 and the connector «G» - Fig. 09-05 of the electric cock, then disconnect the exhaust pipe

«H» - Fig. 09-05 and remove the tank;

09-02

09-03

09-04 09-05

• Disassemble the filter box by disconnecting the connection pipe of the absolute pressure sensor «I» - Fig. 09-06, disconnect the speedometer cable «L» - Fig. 09-06, unscrew the screws «M» - Fig. 09-06 which fasten the sleeves to the throttle bodies on both sides of the motorcycle, then remove the filter box;

• Disassemble the exhaust system;

• Disconnect all the electric connectors of the different users connected to the motor block;

• Disconnect the sparking plug cables;

• Disconnect the connection cables between the starter and the battery;

• Disconnect the two oil recovery pipes «N» - Fig. 09-06 from the frame;

• From the throttle body, disconnect the pipe connected to the fuel filter «O» - Fig. 09-07;

• Disconnect the clutch control transmission cable from the lever on the gearbox cover;

• Disconnect the gearbox lever tie rod from the corresponding selector;

• Place a proper support under the motor block;

09-06

• Unscrew the fastening screws «P» - Fig. 09-08 on the front frame from both sides of the motorcycle;

• Unscrew the screws «Q» - Fig. 09-08 which fasten the front frame to the main frame, then rotate it forward;

• Unscrew the screws «R» - Fig. 09-08/A which fasten the clutch housing to the frame;

• Unscrew the nuts «S» - Fig. 09-08 which lock the side plate connection pin, then extract the pin;

• Unscrew the screw «T» - Fig. 09-08 which fastens the gearbox, then extract the motor/gearbox block;

09-07

09-08

09-08/A

9.2 SPORT 1100 I AND DAYTONA RS

NOTE: The disassembly procedure and

operations are the same for both models.

To disassemble, proceed as follows:

• Remove the passenger saddle by releasing the lock«A» - Fig. 09-09 using the same wrench of the ignition switch;

• Remove the driver saddle using a 6 mm Allen wrench, unscrew from both sides the pin screws «B» - Fig. 09-10 which can be accessed through the holes «C» - Fig. 09-10/A located on the tail side;

09-09

09-10

• Unscrew the screws «D» - Fig. 09-11 from both sides of the motorcycle, then remove the tail;

• Unscrew the screws «E» - Fig. 09-11 which fasten the fairing top to the frame.

NOTE: When unscrewing the above screws, the driving mirrors are released too; remove them.

• Unscrew the screws «F» - Fig. 09-11 which fasten

the fairing from both sides, then extract the fairing;

• Close the fuel cock «G» - Fig. 09-12;

• Disconnect the electric connection of the fuel

reserve indicator «H» - Fig. 09-12;

• Disconnect the fuel pipes from the cock «G» -

Fig. 09-12 and from the pressure adjuster «I» - Fig. 09-13;

• Unscrew the screw «L» - Fig. 09-12, disconnect

the exhaust pipe and remove the tank;

09-10/A

09-11

09-12

• Disconnect the connection pipe of the absolute pressure sensor «M» - Fig. 09-14, disconnect the speedometer

cable«N» - Fig. 09-14, then unscrew the screws «O» - Fig. 09-14 which fasten the sleeves to the throttle bodies on both sides of the motorcycle;

• Unscrew the rear fastening screws «P» - Fig. 09-14, then remove the filter box;

• Disassemble the exhaust system;

• Disconnect all the electric connectors of the different users connected to the motor block;

• Disconnect the sparking plug cables;

• Disconnect the connecting cables between starter and battery;

• Disconnect the two oil recovery pipes «Q» - Fig. 09-14;

09-13

• From the throttle body, disconnect the pipe

connecting to the fuel filter «R» - Fig. 09-15;

• Disconnect the clutch control transmission cable

from the lever on the gearbox cover;

• Disconnect the gearbox lever tie rod from the

corresponding selector;

• Place a proper support under the motor block;

• Unscrew the front frame fastening screws «S» - Fig. 09-16 from both sides of the motorcycle;

• Loosen the screws «T» - Fig. 09-16 which fasten the front frame to the main frame, then rotate it forward;

• Unscrew the screws «U» - Fig. 09-16/A which fasten the clutch housing to the frame;

• Unscrew the nuts «V» - Fig. 09-16 which lock the side plate connecting pin, then extract the pin;

• Unscrew the screw «Z» - Fig. 09-16 which fasten the gearbox top, then remove the motor/gearbox block;

09-14

09-15

09-16 09-16/A

10 ENGINE UNIT

10.1 DISMANTLING THE ENGINE ASSEMBLY

(SPORT 1100 I)

NOTE: pages 68 and 69 show the explosion views of the most important motor assemblies.

To dismantle the engine assembly, proceed as follows: – Loosen screws «A» - Fig. 10-01 that secure the

head cover and remove the cover.

– Turn the crankshaft to the T.D.C. position at the combustion stroke (valves closed) of the L.H. cylinder

Fig. 10-02.

NOTE: This operation can be done even when the gearbox is assembled to the motor block, as the notch position can be checked through the hole shown in Fig. 10-03.

10-01

10-02

10-03

– Remove the two 2 screws «A» and draw our the

shafts of rocker arms «B» easing them out with a screwdriver (Fig. 10-04 and 10-05).

– Disconnect oil delivery piping «A» - Fig. 10-06 to

heads; loosen screw cap «B» - Fig. 10-06 and the underlying stud nut and the 5 nuts «C» - Fig. 10-06; remove the rocker arm support «D» - Fig. 10-06.

– Move the head slightly apart from the cylinder,

remove the 4 oil seals «A» and pull the head out (Fig. 10-07).

– Remove gasket «B» between head and cylinder,

and draw out the cylinder (Fig. 10-08 / 10-09 and

10-10).

10-04

10-05

10-06

10-07

10-09

10-08

10-10

– Release the piston pin circlips, draw out the piston

pin and remove the piston. If necessary use the suitable tool available on the market to extract the piston pin.

– Repeat the same procedure on the R.H. cylinder

(Fig. 10-11).

– Loosen the 4 fastening screws and take off the

alternator front cover «A» - Fig. 10-11.

– Put on the fly wheel the special tool to block it «B»

- Fig.10-12 (cod. 12 91 18 01).

10-11

– Unscrew the central nut «C» which blocks the rotor

(Fig. 10-13).

– Unscrew the three «D» screws of the generator

stator and remove it (Fig. 10-13).

– Remove washer «E» and extract rotor «F» - Fig.

10-14.

NOTE: to prevent rotor demagnetizing, fit rotor into the stator.

10-12

10-13

10-14

– Disconnect the radiator from the engine supports

unscrewing the two screws «A» from both sides (Fig. 10-15).

– Disconnect the oil pipes with a hexagonal spanner

(Fig. 10-16).

– Remove the radiator together with supports and

pipes.

CAUTION When reassembling, replace the aluminium gaskets.

10-15

– Unscrew the 14 screws securing timing system

cover «A» - Fig. 10-17 and remove it.

– The timing marks are highlighted in Fig. 10-18.

Use this marks for valve timing when reassembling.

10-16

10-17

10-18

– Use the special tool to hold timing gear «A» - Fig.

10-19 (part no. 14 92 73 00), unscrew the central nut that holds gear «B» - Fig. 10-19 to camshaft.

– Fit tool «C» - Fig. 10-20 (part no. 12 91 18 01) to the

flywheel and unscrew central nut «D» - Fig. 10-21 that secures timing drive gear «E» - Fig. 10-21 to crankshaft.

– Remove the spline and extract the spacer ring,

(Fig. 10-22).

– After unscrewing the nut holding oil pump drive

gear, extract the three gears along with the chain (Fig. 10-23).

– Remove drive chain tensioner «A» and oil pump

«B» - Fig. 10-24.

– Disassemble the phonic wheel «C» - Fig. 10-24.

IMPORTANT When reassembling the phonic wheel be sure that the milled space «D» - Fig. 10-24/A; is positioned on the opposite side of the censor «E»

- Fig. 10-24/A. Then check with a thickness gauge that the gap between the phase censor “E” and the teeth of the phonic wheel is between 0,6 and 1.2 mm.

10-19

10-20

10-21

0,6 - 1,2 mm

10-22

10-23

10-24

10-24/A

– Unscrew the 3 screws «C» on flange «D» that holds

camshaft «E». Draw out tappets «F» - Fig. 10-25 from their seats and then the camshaft.

– Fit tool «A» (part no. 12 91 18 01) to the flywheel

and tool «B» (part no. 30 90 65 10) to compress clutch springs (Fig. 10-26).

– Unscrew the eight screws «C» holding the ring

gear fitted on the engine flywheel (Fig. 10-26).

– Remove ring gear «D» - Fig. 10-27. When refitting

it later on, remember to line up the marks shown by arrow «E» - Fig. 10-27.

– Take out the clutch plates and the springs from

inside the engine flywheel (Fig. 10-28 and 10-29).

NOTE: Position the special blocking tool «A» (code. 12 91 18 01) as shown in Fig. 10-30.

– Unscrew the six screws «B» that hold flywheel to

crankshaft and remove the flywheel (Fig. 10-30). These screws must withstand considerable loads and stresses and cannot be reused. Fit new screws when reassembling (use Loctite on the screws and torque up to 4÷4.2 Kgm).

10-25

10-26

10-27

10-28

10-3010-29

Before removing the oil sump the oil filter can be removed in this way: – Unscrew the external cap «A» - Fig. 10-31 with the

special tool (Cod. 01929100).

– With the other end if the same tool unscrew the

filter. Using the same tool assembly upside down unscrew and extract the filter «B» - Fig.10-31/A.

WARNING Pay attention positioning the OR when reassembling the external oil cap «A» - Fig.10-31 Replace the OR if damaged.

– Unscrew the 14 peripheral sealing screws «A» of

the oil sump (Fig. 10-31/A), then disassemble it.

10-31

– Disassemble the oil filter support «C» - Fig. 10-32.

Unscrewing the fixing bolts «D» - Fig. 10-32. And removing it the oil pipes «E»- Fig. 10-32.

– Unscrew the bolts «F» - Fig. 10-32 and remove the

flange «G»- Fig. 10-21 and Fig. 10-33.

NOTE: In the first series of model SPORT 1100 I the flange «G» and the oil filter were a whole piece as shown in Table 1. Of page 68.

10-31/A

10-32

10-33

– Unscrew the con-rod screws from inside the crank-

case and remove the connecting rods (Fig. 10-34).

– Unscrew the 8 outer screws «A» holding the rear

flange«B» that supports thecrankshaft (Fig. 10-35). When reassembling, use some Teflon tape on the 2 screw marked with the arrow (Fig. 10-35) to prevent oil from leaking through.

10-34

– Fit tool «C» (part no. 12 91 36 00) as shown in

Fig. 10-35A to remove rear flange «B».

Remove the flange and draw out the crankshaft from the rear.

10-35

10-35A

10.1.1 ENGINE REASSEMBLY

Before reassembling the engine, check all the components carefully, as indicated in the “CHECKING” chapter

10.1.2. – To reassemble, carry out the dismantling operations in reverse order, remembering the following points: – To avoid oil leaks from the 2 lower screws «A», securing the rear crankshaft support flange «B», bind these

screws with Teflon tape (Fig. 10-36). When fitting flanges «B» and «C» on the crankcase, observe the assembly position of holes «D» and

«E» - Fig. 10-37.

– Check play between con-rod shims and crankwebs

(play should be 0.30÷0.50 mm). Install crankshaft in the crankcase and torque up con-rod cap screws at 6.1÷6.6 Kgm.

WARNING Always replace the bolts with new ones because they are heavily loaded and stressed.

10-36

10-37

NOTE: With the CARRILLO connecting rods the wrench setting talk must be 8.5 ±9,3 Kg. Apply “FEL-PRO” lubricant to the screw thread and the surfaces.

10-38

– When refitting flywheel to crankshaft, line up the timing marks as shown in Fig. 10-39 (arrow «A» stamped on

the engine flywheel must be lined up with mark «B» on the crankshaft). Torque up the screws securing the flywheel to the crankshaft at 4÷4.2 Kgm (use Loctite medium compound when reassembling).

10-39

IMPORTANT When reassembling the phonic wheel be sure that the milled space «D» - Fig. 10-40 is positioned on the opposite side of the phase censor «E» - Fig. 10-40; Then check with a thickness gauge that the gap between the phase sensor «E» and the teeth of the phonic wheel is between 0,6 and 1.2mm

– To measure air gap with the engine coupled to the gearbox proceed as follows:

1) measure the distance from sensor seating «A» on crankcase to the surface of flywheel tab «B» - Fig. 10-41

with a gauge;

0,6 - 1,2 mm

10-4110-40

2) measure the distance from sensor tip «C» and

plate «D» of the sensor (Fig. 10-41/A). The difference between the two measures gives actual air gap. If necessary, use more or less shims on sensor seating.

10-41/A

– When reassembling the clutch plate assembly

make sure that the reference marks on a tooth of

the spring pressure plate are lined up with the

reference marks on the flywheel (Fig. 10-42).

– To centre the clutch plates, use the appropriate

tool«A» (part no. 30 90 65 10); tighten the screws

holding the starting ring gear to the flywheel at

1.5÷1.7 kgm torque.

When fitting the starting ring gear to the flywheel,

observe marks «B» shown in Fig. 10-43.

10-42

– The piston has an arrow stamped on it that shows

the correct direction for the piston (the arrow must

be pointing forward as shown in Fig. 10-44).

–

Cylinder and piston should be matched from the

same selection marked with a letter stamped on each

of them (A with A, B with B, C with C) Fig. 10-45.

10-43

10-44

10-45

– Before refitting the rocker arms mount, slip the

4 oil seals «A» into their seats on the stud bolts

(Fig. 10-46).

WARNING

Always replace the OR with new ones.

– Tighten the 5 nuts and the central stud securing

head to cylinder in a cross sequence at 4÷4.2 Kgm

torque (Fig. 10-47).

10-46

– Before refitting the oil sump, accurately position

gasket «A» - Fig. 10-48.

WARNING If gasket is installed incorrectly (both on sump and on spacer), this will lead to immediate damage to engine.

To check the setting of oil pressure relief valve «B»

- Fig. 10-48, see page 66.

Strainer «C» - Fig. 10-48 and oil ducts should be cleaned accurately.

IMPORTANT Always replace the gaskets oil sump and flange.

10-47

10-48

10.1.2 TIMING SYSTEM PHASE-SETTING CHECK

(Fig. 10-49)

To check the timing system phase-setting, proceed as follows:

- allow a clearance of 1.5 mm between the rocking

levers and the valves;

- unscrew the motor pinion fastening nut;

- insert, on the driving shaft slot, the hub code 65 92

84 00 «2» together with the graduated disc code 19 92 96 00 «3», and fasten it to the driving shaft through a screw;

- use a screw to fasten the arrow N. 17 94 75 60 «4»

to the threaded hole of the base;

- on the sparking plug hole of the left cylinder, install

a comparator support «5», then the comparator itself;

- turn the disc clockwise until the left cylinder piston

reaches the top dead centre position (with closed valves), reset the comparator and check that the marks (on the timing gear and the motor pinion) «1» are perfectly aligned. Then, through the gear box inspection hole, check that the mark with letter «S» is correctly aligned with the mark visible in the middle of the hole;

- now, align the arrow tip with the zero “TDC” on the

graduated disc;

- according to the timing chart, check the phase

- screw the support with comparator on the sparking

plug hole on the right cylinder head;

- install the control arrow on the base right side;

- turn the disc clockwise until the mark «D» is

aligned with the mark in the middle of the inspection hole on the gear box (closed valves);

- repeat the operations shown for the left cylinder. When checking is complete, if everything is correct:

- reset the working clearance between the rocking

levers and the valves (suction 0.10 mm, exhaust

0.15 mm);

- remove the graduated disc from the driving shaft

and the arrow from the base;

- remove the support with comparator from the

cylinder head hole, reassemble the sparking plug and complete the assembly.

10-49

10.2 CHECKS

STRIPPING THE HEADS (Fig. 10-50)

To strip heads proceed as follows:

■ place tool «G» (part no. 10 90 72 00) on the upper valve cap and in the middle of the head of the valve to be

removed;

■ turn in tool screw until it is tight, then tap on tool head (where it touches the upper valve cap) with a mallet so

that the two cotters «A» move apart from upper cap «B»;

■ once the two cotters «A» are apart, tigthen the screw further until you can lift the cottters out of the valve seats;

loosen the tool and take it off the head; then draw out upper cap «B», inner spring «C», outer spring «D», lower cap «E» and eventually the shims, and valve «F» from inside the head.

10-50

HEADS

Check that:

■ the surfaces in contact with the cover and with the cylinder are not scratched or damaged thus preventing a

perfect seal;

■ check that the tolerance between the valve guide holes and the valve stems are within the prescribed limits;

■ check the state of the valve seats.

Ø8.000÷8.022 mm

Ø7.980÷7.965

45°30'±5'

EXHAUST VALVE

Ø39.3÷39.5

10-51

INLET VALVE

45°30'±5'

Ø7.987÷7.972

Ø46.3÷46.5

VALVE GUIDE

To extract the valve guides from the heads, use a punch. The valve guides should be replaced when the clearance between the above and the stems cannot be eliminated by replacing the valves alone.

To fit the valve guides on the heads:

■ heat the head in an oven to approximately 60°C, then lubricate the valve guides;

■ fit the piston rings;

■ press the valve guides with a punch; pass a stem borer in the holes of the valve stems, to restore the prescribed

internal diameter (Fig. 10-51).

The allowance between the seat on the head and the valve guide must be 0.046÷0.075 mm.

DATA TABLE FOR VALVE AND GUIDE COUPLINGS

internal valve guide dia. valve stem dia. fitting clearance

mm mm mm

Inlet 7,972÷7,987 0,013÷0,050

8,000÷8,022

Exhaust 7,965÷7,980 0,020÷0,057

VALVE SEATS

The valve seats should be milled. The seat inclination is 45°±5'. After milling, to obtain a good coupling and a perfect seal between the ring nut and the valve mushrooms, use a honing machine.

30°

Ø41÷41.1

15°

45°±5'

Ø43.9÷44.1

Ø46

Ø47.04

0,5

0,3

30°

Ø36÷36.1

15°

45°±5'

Ø36.4÷36.6

Ø39

Ø41.77

1,25

0,8

Detail of exhaust valve seat Detail intake valve seat

10-52

INSPECTION OF VALVE SPRINGS

Check that the springs are not deformed and have not lost their load:

External spring

■ free, has a length of 40,3;

■ with closed valve, has a length of 35 mm and must give a load of 20,33÷22,47 kg;

■ with open valve, has a length of 24,4 mm and must give a load of 60,8÷67,2;

■ compressed, has a length of 21 mm.

Internal spring

■ free, has a length of 37,9 mm;

■ with closed valve, has a length of 33,5 mm and must give a load of 9,215÷10,185;

■ with open valve, has a length of 22,9 mm and must give a load of 31,35÷34,65;

■ compressed, has a length of 19.6 mm.

If the springs do not satisfy the above specifications they must be replaced.

Kg. 20.33÷22.47

Kg. 60.8÷67.2

EXTERNAL SPRING INTERNAL SPRING

ROCKER ARM PIN ROCKER ARM

Ø1,5

41,5

Ø4

24.4 mm

35 mm

40.3 mm

Kg. 9.215÷10.185

Kg. 31.35÷34.65

Ø14.994÷14.983

33.5 mm

37.9 mm

22.9 mm

10-53

Ø15.032÷15.059

Ø6 P.1MA

10-54

CHECK SPRING PACK (Fig. 10-55)

When the valve seats on the heads have been milled it is necessary, after fitting the valves on the heads, to check that the springs are compressed between 34,7÷35 mm; to obtain this value insert «A» washers cod. 14 03 73 00 of thicknesses 0.3 mm.

34,7÷35

TIMING DATA

The timing data (referring to the control clearance of 1,5 mm between rocker arms and valves) are as follows (see Fig. 10-56):

Intake:

■ open 22° before TDC (top dead center)

■ close 54° after BDC (bottom dead center)

Exhaust:

■ open 52° before BDC

■ close 24° after TDC

■ intake 0.10 mm (USA version: mm 0,05)

■ exhaust 0.15 mm (USA version: mm 0,05)

END OF DISCHARGE AFTER T.D.C.

DISCHARGE START BEFORE B.D.C.

10-55

T.D.C.

INTAKE START BEFORE T.D.C.

INTAKE END AFTER B.D.C.

B.D.C.

10-56

DIAMETER OF CAMSHAFT BEARINGS AND THEIR HOUSINGS IN CRANKCASE

Ø CAMSHAFT JOURNAL

Ø HOUSING IN CRANKCASE FITTING CLEARANCE

mm mm mm

Timing side 47,000 ÷ 46,984 47,025 ÷ 47,050 Drive side 32,000 ÷ 31,984 32,025 ÷ 32,050

TAPPET-GUIDE IN CRANKCASE - COUPLING DATA

I/D OF GUIDE HOUSING O/D OF TAPPETS FITTING CLEARANCE

mm mm mm

Original 22,021 ÷ 22,000 21,996 ÷ 21,978 0,004 ÷ 0,043 O/S on dia. mm 0,05 22,071 ÷ 22,050 22,046 ÷ 22,028 0,004 ÷ 0,043 O/S on dia. mm 0,10 22,121 ÷ 22,100 22,096 ÷ 22,078 0,004 ÷ 0,043

0,025 ÷ 0,066

CYLINDER WEAR CHECK (Fig. 10-57)

The measurement of the cylinder diameter must be made at three heights, turning the feeler gauge by 90°. It is also important to check that the cylinders and the pistons are of the same selection class (A, B, C).

Ø 92.000 ÷ 92.018

1st - MEASUREMENT

2nd - MEASUREMENT

3rd - MEASUREMENT

Grading cylinder diameter

GRADE A GRADE B GRADE C

92,000÷92,006 92,006÷92,012 92,012÷92,018

Grading piston diameter

GRADE A GRADE B GRADE C

91,954÷91,960 91,960÷91,966 91,966÷91,972

91.954 ÷ 91.972

control measurement for selection

10-57

NOTE: The «A», «B», «C» grade cylinders must be coupled with the corresponding pistons in the grades «A», «B», «C» (Fig. 10-46).

The grading measurements indicated in the tables must be taken at 14 mm from the lower edge of the piston, at right-angles to the gudgeon pin axis.

Maximum cylinder ovalization allowed: ...............................................................................................0.02 mm.

Maximum clearance allowed between cylinder and piston: ................................................................0.08 mm.

PISTONS (Fig. 10-58)

During overhauls, the incrustations must be removed from the piston crowns and the piston ring seats; check the existing clearance between the cylinders and the pistons with the grading diameter; if it is higher than that indicated it is necessary to replace the cylinders and the pistons. The engine pistons must be balanced; a weight difference of 1.5 grams is allowed.

1.52 ÷ 1.54

2.975 ÷ 2.990

3.02 ÷ 3.04

57.9 ÷ 58.1

Ø21.994 ÷ 21.998

1.475 ÷ 1.490

Ø92

0.40 ÷ 0.65

0.30 ÷ 0.60

Values in mm

22.006 ÷ 22.011

Coupling data

Dia. Dia. CLEARANCE BETWEEN

PISTON PIN PISTON HOLES PISTON PIN & HOLES

mm mm ON PISTON mm

21,994 22,006

0,008÷0,017

21,998 22,011

OIL SCRAPER COMPRESSION RINGS

Each piston is fitted with: 1 upper piston ring, 1 intermediate slotted piston ring, 1 oil control ring. The piston rings must be positioned with the open ends offset to each other.

Assembly clearance measured between ring thickness and piston groove.

Compression ring and oil scraper:0,030÷0,065 mm.

Aperture between the ends of the piston rings fitted on the piston

Upper compression ring and slotted ring:

........................................................0.40÷0.65 mm.

Oil control ring: ................................0.30÷0.60 mm.

10-58

Fitting of the piston in the little-end bearing (Fig. 10-59)

When the piston is fitted in the little-end bearing, the part marked in the figure with the arrow «A» must be turned towards the exhaust manifold.

10-59

CONNECTING RODS

When overhauling the connecting rods, carry out the following checks:

■ the condition of the bushings and the clearance

between these and the gudgeon pins;

■ parallelism of the axes;

■ connecting rod bearings.

The bearings are of the thin shell type, in babbitt alloy that cannot be adjusted; if there are any traces of seizing or wear they must be replaced. If the bearings are replaced it may be necessary to mill the crankshaft pin. Before grinding the crankshaft pin, it is advisable to measure the pin diameter in correspondence to the maximum wear (Fig. 10-62); this is to establish to which undersize class the bearing should belong and to what diameter the pin should be ground.

NOTE: On the model SPORT CORSA 1100 the CARRILLO connecting road Cod.3006154 see Fig. 10-61.

Table of connecting rod weights - Fig. 10-60

Con-rod total Con-rod small end Con-rod big end Weight selection weight weight (reciproc.) weight (rotating) color coding

g. 634±2 g. 474±2 Orange g. 630±2 g. 160 g. 470±2 Light blue g. 626±2 g. 466±2 White

25.021

25.000

139.975 ÷ 140.025

47.130

47.142

23.850

23.800

23.850

23.800

4.44 ÷ 4.57

25.093

25.068

23.800

23.600

After pressing it down ream to:

22.007 ÷ 22.020

1.535 ÷ 1.544

47.130

47.142

18.95 ÷ 19.20

10-60

CARRILLO connecting road

47.0135

47.0132

23.825

23.775

22.0023

22.0026

139,985 ÷ 140,015

Thicknesses of the connecting rod bearings.

NORMAL BEARING DIA.

UNDERSIZED BY MM

(PRODUCTION) mm

from 1,535 1,662 1,789 1,916 to 1,544 1,671 1,798 1,925

bearings for connecting rod pin

0,254 0,508 0,762

23.825

23.775

10-61

10-62

*CRANKSHAFT PIN DIAMETER:

STANDARD DIA. UNDER SIZED 0.254 mm UNDER SIZED 0.508 mm UNDER SIZED 0.762 mm

44,008÷44,020 43,754÷43,766 43,500÷43,512 43,246÷43,258

*Gudgeon pin and bushing coupling data

INTERNAL DIA. OF

PRESSED AND

MACHINED mm

GUDGEON PIM

DIA. mm

22,007 21,994

CLEARANCE BETWEEN

GUDGEON PIN AND

BUSHING mm

0,009÷0,026

22,020 21,998

*The technical data of Model SPORT CORSA 1100 are listed in the table of page 94. Check parallelism of the axes (Fig. 10-63 / 10-63/A)

Before assembling the connecting rods, check the quadrature, i.e. check that the little-ends and the big ends of the connecting rods are parallel and coplanar. Any minimum deformities can be corrected by adjusting the connecting rod stem. The maximum parallelism and coplanar error of the two axes of the little-end and the big end measured at the distance of 200 mm must be ±0.10 mm.

FITTING OF THE CONNECTING RODS ON THE DRIVE SHAFT

The assembly clearance between the bearing and the connecting rod pin ranges from a minimum of 0.022 mm to a maximum of 0.064 mm. The clearance between the connecting rod shim adjustment and those of the crankshaft is 0.30÷0.50 mm. Fit the connecting rods on the crankshaft, tighten the screws on the caps with a dynamometric wrench using a tightening torque of 6,1÷6,6 kgm.

NOTE: When the CARRILLO connecting rods are mounted the wrench setting talk must be 8.5÷ 9,3 Kg.

Areas to be machined off in order to achieve equal weight and weight distribution for balancing on connecting rods.

Tightening torque for oiled screw: 60 ÷ 65 Nm (Kgm 6,1 ÷ 6,6)

// 0.10 X Y

200

36 min.

Bush edge must be within this sector

30°

18 min.

22,007 ÷ 22,020

NOTE: Accurately determine the parallelism of axes X-X/Y-Y = 0.100 over 200 mm.

10-63

// 0.10 X Y

200

Tightening torque for screw: Kgm 8.5 ÷ 9,3

NOTE: Accurately determine the

parallelism of axes X-X/Y-Y = 0.100 over 200 mm.

10-63/A

CRANKSHAFT

Examine the surfaces of the main journals; if they are grooved or ovalized, the journals must be ground (following the undersize tables), and replace the flanges complete with the main bearings. The main bearings undersizing scale is as follows: 0.2-0.4-0.6 (see tables on page 64). The assembly clearances are the following:

■ between main bearing and journal timing side 0.028÷0.060 mm

■ between main bearing and journal flywheel side 0.040÷0.075;

■ between bearing and connecting rod pin 0.022÷0.064 mm.

When grinding the crankshaft journals it is necessary to maintain the value of the connecting throw on the shoulders that is: 2÷2.5 mm for the connecting rod pin, 3÷3,2 mm for the main journal on the flywheel side and

1.5÷1.8 mm for the main journal on the timing system side.

Diameter of main journal on flywheel side Diameter of main journal on timing system side

NORMAL

PRODUCTION

53.970 53.770 53.570 53.370

53.951 53.751 53.551 53.351

UNDERSIZED BY mm

0.2 0.4 0.6

NORMAL

PRODUCTION

37.975 37.775 37.575 37.375

37.959 37.759 37.559 37.359

UNDERSIZED BY mm

0.2 0.4 0.6

10-64

WEIGHT CHECK FOR CRANKSHAFT BALANCING

The connecting rods complete with screws must have a balanced weight. There is a tolerance of 4 grams. (See “Table of connecting rod weights” Pag. 61) For a static balancing of the crankshaft, the pin must bear a weight of: 1,870 kg.

NOTE: When the CARRILLO rods are mounted, in order to set the static balance of the motor shaft a weight of 1.6Kg. must be applied on the button of the crank.

Ø54.000 ÷ 54.019

Identification code

Ø53.970 ÷ 53.951

53.800÷53.819 M 2

53.600÷53.619 M 4

53.400÷53.419 M 6

0.6 0.4 0.2

Undersizing by mm

Internal dia. of main bearing for spare parts

Identification code

* Ø44.008 ÷ 44.020

Ø37.959 ÷ 37.975

48.000 ÷ 48.100

CRANKSHAFT COUPLING CLEARANCE= m/m 0,040 ÷ 0,075

37.800÷37.816 M 2

37.600÷37.616 M 4

37.400÷37.416 M 6

button is between 44.008 ÷ 44.012 mm.

* On the SPORT CORSA 1100 model, if the CARRILLO connecting rod are mounted the diameter of the crank

Internal dia. of main bearing for spare parts

38.969 ÷ 40.031

0.6 0.4 0.2

Undersizing by mm

CRANKSHAFT COUPLING CLEARANCE= m/m 0,028 ÷ 0,060

Ø38.000 ÷ 38.016

10-65

CHECK CRANKCASE (FLYWHEEL FLANGE SIDE) FOR OIL LEAKS

In the event of oil leaks from the rear part of the crankcase (flywheel area), check the following:

■ that the seal ring on the flange on the flywheel side is not damaged;

■ that there is no blowing in the crankcase. To make this check, rest the engine on a bench with the flywheel side

uppermost, after removing the flywheel from the crankshaft;

■ fill the upper part of the crankcase with water;

■ blow through the breather pipe with low pressure compressed air (to avoid dislodging the oil seals), taking care

to hold the seal ring with two fingers;

■ In presence of porosity small bubbles will be seen. In this case the porosity must be filled with a suitable

commercial compound.

OIL DELIVERY PUMP

In case of improper operation of the oil pump, check accurately the following: depth of gears should be

15.973÷16.000 mm; gear housing in pump body should be 16.032÷16.075 mm. If not within the above sizes, the parts should be replaced.

9.985 ÷ 10.000

26.250 ÷ 26.290

15.973 ÷ 16.000

16.032 ÷ 16.075

26.340 ÷ 26.390

21.989 ÷ 22.002

21.972 ÷ 21.993

9.990 ÷ 10.002

22.330 ÷ 22.350

10.013 ÷ 10.035

10-66

OIL PRESSURE TRANSMITTER

This is fitted on the crankcase, and is connected to the pilot light on the control panel by electric cables; its purpose is to signal insufficient pressure in the lubrication circuit. When the light on the control panel comes ON (with the engine running), this indicates that the pressure has fallen below the set limits; it is necessary to stop the vehicle immediately and check the cause of the pressure drop.

CHECK OIL PRESSURE TRANSMITTER (Fig. 10-67)

To check the efficiency of the transmitter, fit it on the tool with a gauge fitted; connect the positive lead (+) of the tester to the transmitter and the negative lead (–) to earth, then blow compressed air through the coupling of the above tool, making sure that the indicator on the tester moves when the pressure (looking at the gauge) reaches 0.15÷0.35 kg/sq.cm.

10-67

ENGINE OIL PRESSURE ADJUSTMENT VALVE (Fig. 10-68 / 10-69 /10-70)

Check the oil pressure valve calibration. The oil pressure adjustment valve «A» is screwed to the oil sump. It must be calibrated to allow a pressure in the delivery circuit of 3,8÷4,2 kg/sq.cm. To test the calibration, it is necessary to fit the valve on the appropriate tool with a gauge fitted; blow compressed air through the tool coupling and make sure that the valve opens precisely at the set pressure. If the valve opens at a lower pressure, place one or more «B» shims under the spring; if it opens at a higher pressure, increase the number of «C» washers.

10-68

THERMOSTATIC VALVE (Fig.10-70/A)

The thermostatic valve opens the oil passage to the radiator when the temperature exceeds 71°c.

Bulb characteristic

10-7010-69

Stroke mm.

Temperature °C

Opening start

10-70/A

LUBRICATION

10-71

ENGINE BLOCK AND COVERS

Tav. 1

HEADS

Tav. 2

CYLINDERS AND CONNECTING RODS

Tav. 3

DISTRIBUTION

Tav. 4

11 ENGINE UNIT (DAYTONA RS and V10 CENTAURO)

11.1 ENGINE DISMANTLING

NOTE: On pages 100 / 101 the Assembly drawings of the most important parts of the engine are shown.

For disassemble of the engine follow these steps: – Remove the front cover from the timing belts – Place the engine in the TDC position for the left

cylinder detonation phase. The TDC position can be found by referring to the engine flywheel Fig. 11-01 or, more precisely, by inserting a feeler gauge in contact with the piston head using the appropriate tool cod. 30 94 82 00 inserted in the spark plug hole.

– Check the timing references as indicated in

Fig. 11-02; if the marks on the pulleys, on the

hubs and on the shafts are not clearly visible or are

missing, it is necessary to restore these assembly

reference marks with indelible paint, according to

the lines No.1, 2 and 3 indicated in the drawing. – The above applies for subsequent reassembly, if it

is not necessary to replace any of the timing

system parts or only the belts need replacing for

periodic maintenance. If the belts already fitted on

the engine are to be used again, when they are

being removed they should be given reference

marks with paint which must be observed during

reassembly.

11-01

11-02

– Remove the head caps. – Using the appropriate seal tool «A» - Fig. 11-03 cod. 30 92 73 00, loosen the central securing nuts on the cam

shaft pulleys. – Using the appropriate seal tool «B» - Fig. 11-04 cod. 30 92 76 00, loosen the nut securing the pulleys on the

service shaft.

11-03

11-04

– The pulley drive gear on the cam shafts can be removed using the appropriate extractor tool cod. 30 94 83 00

«C» - Fig. 11-05 / 11-05/A. – Loosen the belt stretcher «D» - Fig. 11-05 and remove the timing system command pulleys «E» - Fig. 11-06.

11-05

MULTIPLE EXTRACTOR COD. 30 94 83 00

pulley services shaftØ40

11-06

1 Screw 2 Nut 3 Body 4 Screw TE M4x35 5 Screw TCEI M8x30 6 Screw TE M5x35 7 NutM5 8 NutM4

Ø32

cam shaft pulley hub

Ø27

oil pump command gear

6 3 2

7 1

11-05/A

– Remove the alternator and unscrew the seal screws

on the timing side cover (Fig. 11-07).

– The timing references between the gear on the

engine shaft and the gear on the service shaft are indicated with the arrows «1» and «2» - Fig. 11-08.

– With the piston positioned at (Top Dead Centre

T.D.C.) at the ignition phase, the service shaft must be turned so that the spline «3» - Fig. 11-08 is pointing downwards and the centring holes «4»

- Fig. 11-08 will be aligned with the centre line of the right cylinder.

11-07

– Using the appropriate seal tool «A» - Fig. 11-09

cod. 12 91 18 01, lock the engine shaft by means of the starting ring gear .

– Loosen the seal nut «A» - Fig. 11-10 and remove

the gear «B» - Fig. 11-10 from the engine shaft .

11-08

11-09

11-10

– Using the seal tool «A» - Fig. 11-11 cod. 30 92 76

00, unscrew the central nut on the oil pump command gear and with the appropriate extractor

«C» - Fig. 11-05 cod. 30 94 83 00 remove the gear.

NOTE: When reassembling, the oil pump

and the pump shaft command gear cones must

be thoroughly degreased with trichlorethylene; “Loctite 601” must be applied to the shaft and on the cones threading; lock the nut with a tightening torque of 2÷2.2 kgm using the seal tool «A» - Fig. 11-11 cod. 30 92 76 00.

ATTENTION

11-11

During the dismantling and reassembly operations, always use the locking tools to avoid any overloading of the Ergal gear teeth; otherwise the gears could be permanently damaged.

– Extract the service shaft timing command gear

«A» - Fig. 11-12.

– Extract the phonic wheel «B» - Fig. 11-12.

11-12

0,6 - 1,2 mm

IMPORTANT When reassembling the phonic wheel be sure that the milled space «C» - Fig.11-13 is positioned on the other side of the face censor «D» - Fig. 1113, then check with a thickness gauge the gap between the phase sensors «D» and the teeth of the phonic wheel is between 0.6 and 1.2mm.

– Remove the seal screws «E» - Fig. 11-12 from the

check flange and extract the service shaft «F» -

Fig. 11-12.

11-13

– Remove the cylinder heads as follows: – Extract the articulation pins «A» - Fig. 11-14 on the

rocker arms «B» - Fig. 11-14 and remove the rocker arms and their shims «C» - Fig. 11-14.

– Remove the 2 nuts «E» - Fig. 11-14 (dia. 8x1.25)

and subsequently the 4 seal nuts «D» - Fig. 11-14 (dia.10x1.5) on the rocker arm support «F» - Fig.

11-14 and extract the latter.

11-14

NOTE: When reassembling reinsert the caps of the valves («A» - Fig. 11-15).

11-15

– Remove the 4 OR rings on the cylinder seal stud bolts (Fig. 11-16). – Extract the head, the gasket between the head and the cylinder, and the cylinder (Fig. 11-17).

11-16

– Remove the gudgeon pin catches, the gudgeon pin and the piston (Fig. 11-18). When reassembling,

remember that the arrow on the piston head must be turned towards the discharge (Fig. 11-19).

11-17

11-18

11-19

– Fit tool «A» (part no. 12 91 18 01) to the flywheel

and tool «B» (part no. 30 90 65 10) to compress clutch springs (Fig. 11-20).

11-20

– Unscrew the eight screws «C» holding the ring

gear fitted on the engine flywheel (Fig. 11-20).

– Remove ring gear «D» - Fig. 11-21. When refitting

it later on, remember to line up the marks shown by arrow «E» - Fig. 11-21.

11-21

11-22

– Take out the clutch plates and the springs from

inside the engine flywheel (Fig. 11-22).

NOTE: Position the special blocking tool «A» (code. 12 91 18 01) as shown in Fig. 11-23.

– Unscrew the six screws «B» - Fig. 11-23 that hold

flywheel to crankshaft and remove the flywheel. These screws must withstand considerable loads and stresses and cannot be reused. Fit new screws when reassembling (use Loctite on the screws and torque up to 4÷4.2 Kgm).

11-23

Before removing the oil sump the oil filter can be removed in this way: – Unscrew the external cap «A» - Fig. 11-24 with the

special tool (Cod. 01 92 91 00).

– With the other end if the same tool unscrew the

filter. Using the same tool assembly upside down unscrew and extract the filter Fig.11-25.

WARNING Pay attention positioning the OR when reassembling the external oil cap «A» - Fig.11-24 Replace the OR if damaged.

– Unscrew the 14 peripheral sealing screws «A» of

the oil sump (Fig. 11-25). then disassemble it.

11-24

– Disassemble the oil filter support «C» - Fig.11-26.

Unscrewing the fixing bolts «D» - Fig. 11-26. And removing it the oil pipes «E» - Fig. 11-26.

– Unscrew the bolts «F» - Fig.11-26 and remove the

flange «G» - Fig. 11-26 and Fig. 11-27.

11-25

11-26

11-27

– Unscrew the con-rod screws from inside the

crankcase and remove the connecting rods. When reassembling always replace the bolts with new ones because they are heavily loaded and stressed. Tighten the bolts with wrench setting talk of 8.5 ÷ 9,3 Kgm (Fig. 11-26).

11-28

– Unscrew the 8 outer screws «A» holding the rear

flange «B» that supports the crankshaft. When reassembling, use some Teflon tape on the 2 screw marked with the arrow (Fig. 11-29) to prevent oil from leaking through.

11-29

– Fit tool «C» (part no. 12 91 36 00) as shown in Fig.

11-30 to remove rear flange «B».

Remove the flange and draw out the crankshaft

11-30

from the rear.

11.2 ENGINE REASSEMBLY

Before reassembling the engine, check all the components carefully, as indicated in the “CHECKING” chapter 11.4. – To reassemble, carry out the dismantling operations

in reverse order, remembering the following:

– To avoid oil leaks from the 2 lower screws «A» -

Fig. 11-31, securing the rear engine shaft support flange «B» - Fig. 11-31, bind these screws with Teflon tape. When fitting the flanges «B» and «C» - Fig. 11-32 on the crankcase, observe the assembly position of the holes «D» and «E» - Fig. 11-32.

11-31

After having assembled the motor shaft in the base, lock the caps coupling screws at Kgm 8,5÷9,3 torque.

WARNING In consideration of the high load and stresses these screws undergo, they must be replaced with new ones.

NOTE: Apply some “FEL-PRO” lubricant on the screw thread and on the laying surfaces.

IMPORTANT In order to obtain a correct phasing of the system be sure that the milled space «F» - Fig. 11-33 is positioned on the opposite side of the phase censor «G» - Fig. 11-33; then check with a thickness gauge that the gap between the phase censor and the teeth of the phonic wheel is between 0.6 and 1.2mm.

11-32

0,6 - 1,2

11-33

Timing cover securing screws

Replace the timing cover securing screws positioning them according to the lengths indicated in the Fig. 11-34. – Before inserting the pistons in the cylinders, position the rings as indicated in the Fig. 11-35.

35 mm

20 mm

25 mm

35 mm

– When replacing the cylinder head, take care to

position the gaskets correctly to avoid blocking the oil passages shown in the Fig. 11-36; fit the two cylinder head centering bushings.

– Before replacing the rocker arm support frame, fit

the 4 OR rings on the tie rods as indicated in the

Fig. 11-37.

IMPORTANT When reassembling always reinsert new OR rings.

11-3511-34

11-36

11-37

– Fit the frame and lock the 4 nuts (dia.10x1.5) to the

torque of 4.2÷4.5 kgm in a cross-over sequence and subsequently the two nuts (dia. 8x1.25) at the torque of 2.2÷2.3 kgm (Fig. 11-38).

11-38

– When refitting the flywheel on the engine shaft, observe the reference marks as indicated in the Fig. 11-39 (

The arrow «A» is hobbed on the engine flywheel must be aligned with a mark «B» on the motor shaft).

– Tighten the bolts blocking the fly wheel on the motor shaft with a wrench setting talk of Kgm from 4÷4.2

(assemble with locktite medium grade).

– When reassembling the clutch disk pack take care that the reference marks on a tooth of the spring-holding

plate are lined up with the reference marks on the flywheel (Fig. 11-40). – To centre the clutch disks, use the appropriate tool «A» - Fig. 11-41 cod. 30 90 65 10; – Screw the seal screws on the starting ring gear to the flywheel with a tightening torque of 1,5 ÷ 1,7 kgm.

11-39

– Mounting the starting crown on the fly wheel pay attention to the signs «B» shown on Fig. 11-41.

11-40 11-41

– The cylinder and piston group must be assembled

matching the same selection class hobbed on both components (A with A. B with B and C with C) Fig.

11-42.

11-42

Before mounting the oil sump carefully position the

gasket «A» - Fig. 11-43.

WARNING The wrong assembly of the gasket (either of the oil sump or on the flange) will seriously damage the engine.

To check the set up of the oil pressure control valve «B» - Fig. 11-43 see page 97.

The strainer «C» - Fig. 11-43 in the oil ducts must be

11-43

carefully cleaned.

IMPORTANT When reassembling always change the gasket of the oil sump and the flange.

11.3 ENGINE TIMING

– If none of the timing system components have been replaced, timing should be carried out as described in Par.

11.1 “ENGINE DISMANTLING”.

– To stretch the belts, fit the tool «1» - Fig. 11-44 cod. 30 94 86 00, as indicated in the figure, after loosening

the 3 belt-stretcher seal nuts by a few turns.

Using a dynamometric wrench, apply a torque of 0.4÷0.48 kgm to the tool and under these conditions tighten in

the following order: – pin «A» nut – fulcrum «B» stud bolt; – screw «C». The belts must be replaced every 30,000 km without fail, or when, during a inspection, there is any sign of wear or damage.

NOTE: The belts must always be stretched with the piston in the TDC position, in the combustion

phase (closed valve) or with the upper cam shaft drive pulley without inner gears as shown in Fig. 11-44.

– If any of the timing components have been replaced,

or for an accurate adjustment of the timing, proceed

as below.

DETERMINATION OF THE TDC AND TIMING

The TDC is indicated by the marks on the engine flywheel (Fig. 11-45).

11-44

11-45

For a more accurate determination of the TDC it is however necessary to proceed as follows: place a feeler gauge with support cod. 30 94 82 00 in the spark plug hole of the left cylinder Fig. 11-46 and position the piston at TDC. Fit the graduated disk cod. 19 92 96 00 on the crankshaft with hub cod. 30 94 96 00 and relative index cod. 17 94 75 60. – Turn the crankshaft until the piston is lowered by 3 mm and note the degrees indicated on the graduated disk

index (e.g. 22 degrees). – Turn the drive shaft in the opposite direction until the piston is lowered by 3 mm and read the number of degrees

on the graduated disk (e.g. 18 degrees). – The exact position of the TDC is therefore indicated on the graduated disk by the middle between the two

extreme readings and is given by (22°+18°): 2=20°. Starting therefore from the position of 22° or 18° move the drive shaft forwards or backwards by 20°; in this position zero the graduated disk holding the crankshaft still.

22°

20°

11-47

Pos. PMS

20°

18°

11-46

– With the engine without the rocker arms, fit a feeler

gauge on the left (Induction Control ducket) cylinder discharge command points using the tool cod. 69 90 78 50 as indicated in the Fig. 11-47. The upper timing command pulleys must be without the inner drive gears as indicated in the Fig. 11-47. The drive belts must be stretched correctly.

– After placing the engine in the TDC position, in the

left cylinder combustion phase, check that reference «1» - Fig. 11-48 on the service shaft is lined up with reference «2» - Fig. 11-48 on the timing cover.

11-48

– For the model V10 CENTAURO and for the models

DAYTONA RS with special instructions for USA.

SWITZERLAND and SINGAPORE, starting from

the Top Dead Centre T.D.C. left cylinder, indicated

inFig. 11-49. Turn the motor shaft clockwise (seen

from the front) and position it to 49° 30 + 1° before

the bottom dead centre (B.D.C.) Fig. 11-50. – For the model DAYTON RS (excluding the version

with specifications for USA. SWITZERLAND and

SINGAPORE) starting from the Top Dead Centre

(T.D.C) left cylinder indicated in Fig. 11-49, turn

the motor shaft clockwise (seen from the front) and

position it to 69° 30’+1° after the bottom dead

centre Fig. 11-51.

11-49

11-50 11-51

– Using the appropriate tool cod. 30 92 72 00, turn

the left cylinder (Fig. 11-52) cam shaft in an anti-

clockwise direction until the cam, starting from the

lowered position (feeler gauge reading on the

points 0), gives a lift value tappet exhaust of

induction of 1mm.

– At this point insert the drive gear «A» - Fig. 11-53

in the toothed pulley «B» - Fig. 11-53, finding the

free insertion position by turning just the gear. – Turn the drive shaft 2 turns in a clockwise direction,

return the left cylinder to the TDC position in the

combustion phase and check timing again (1 mm

lifting of exhaust tappet at 49°30'±1° before BDC.

For DAYTON RS (excluding the version with

specifications for USA. SWITZERLAND and

SINGAPORE) lift 1mm for the valve tappet induction

at 69° 30’+1° after the Bottom dead centre (B.D.C).

11-52

11-53

RIGHT CYLINDER TIMING

– Position the comporator on the exhaust of the induction

valve tappet of the right cylinder (Fig. 11-54).

11-54

– With the graduated disk zeroed with respect to the «A» index and the engine in the TDC position (combustion

phase) of the left cylinder, fit a second index «B» in the position shown in Fig. 11-55 (90° from «A» index).

Turn the crankshaft in a clockwise direction by 270°; this gives the TDC position (combustion phase) of the

right cylinder, with the graduated disk zeroed with respect to the «B» - Fig. 11-56 index.

11-55 11-56

– For the model V10 CENTAURO and DAYTONA RS (excluding the version with specifications for USA.

SWITZERLAND and SINGAPORE) do the phasing as already explained for the left cylinder (elevation of 1mm.

Of the exhaust value tappet at 49° 30’+1° before the Bottom Dead Centre B.D.C.) (Fig. 11-57). – For the model DAYTON RS (excluding the version with specifications for USA.SWITZERLAND and

SINGAPORE) do the phasing as already explained for the left cylinder (lift 1mm. The induction valve tappet

at 69°-30’+1° after the Bottom Dead Centre B.D.C.) (Fig. 11-58).

11-57 11-58

Subsequently check the right cylinder timing as already indicated for the left cylinder and complete the reassembling of the engine unit (Fig. 11-59 / 11-60).

11-59 11-60

COMBUSTION SEQUENCE

During engine timing remember that the correct combustion sequence is the following: 1 – Left cylinder combustion 2 – After 270° (360°–90°) right cylinder combustion 3 – After 450° (360+90°) left cylinder combustion 4 –

After 270° (360°–90°) right cylinder combustion, etc.

CRANKSHAFT ROTATION DEGREES

450°

270°

11-61

11.4 CHECKS

HEADS (Fig. 11-62)

Check that:

■ the surfaces in contact with the cover and with the

cylinder are not scratched or damaged thus

preventing a perfect seal;

11-62

■ check that the tolerance between the valve guide holes and the valve stems are within the prescribed limits

(Fig. 11-63);

■ check the state of the valve seats.

EXHAUST

Ø 6.965 ÷ 6.980 mm

Ø 29.400 ÷ 29.600 mm

11-63

45°÷ 45° 15'

INTAKE

Ø 7.000 ÷ 7.022

Ø 6.972 ÷ 6.987

53.800 ÷ 54.200

Ø 13.094 ÷ 13.105 mm

45° ÷ 45° 15'

Ø 33.400 ÷ 33.600 mm

VALVE GUIDE

To extract the valve guides from the heads, use a punch. The valve guides should be replaced when the clearance between the above and the stems cannot be eliminated by replacing the valves alone.

To fit the valve guides on the heads:

■ heat the head in an oven to approximately 60°C, then lubricate the valve guides;

■ fit the piston rings;

■ press the valve guides with a punch; pass a stem borer in the holes of the valve stems, to restore the prescribed

internal diameter. The allowance between the seat on the head and the valve guide must be 0.057÷0.064 mm.

DATA TABLE FOR VALVE AND GUIDE COUPLINGS

internal valve guide dia. valve stem dia. fitting clearance

mm mm mm

Inlet 6,972÷6,987 0,013÷0,050

7,000÷7,022

Exhaust 6,965÷6,980 0,020÷0,057

VALVE SEATS (Fig. 11-64)

The valve seats should be milled. The seat inclination is 90°. After milling, to obtain a good coupling and a perfect seal between the ring nut and the valve mushrooms, use a honing machine.

Detail of exhaust valve seat

Ø26

6°

90°

1.1 ÷ 1.2

Ø26.7 ÷ 26.9

Ø29

Detail intake valve seat

Ø29.5

15°

90°

1.1 ÷ 1.2

Ø30.9 ÷ 31.1

Ø33

11-64

Lateral clearance between rocker arms and rocker arm support housing 0.2 mm (Fig. 11-65); the shim washers are supplied with thicknesses of 1 mm and

1.2 mm.

ROCKER ARM PIN ROCKER ARM

0,2 mm

11-65

Ø12.000 ÷ 12.018

27.00 ÷ 24.03

Ø11.983 ÷ 11.994

11-66

1 = Intake start before TDC 2 = End of exhaust after TDC 3 = Exhaust start before BDC 4 = Intake end after BDC

23°30

12°30

49°30

57°30

TIMING DATA For the models V10 CENTAURO and DAYTON RS (excluding the version with specifications for USA. SWITZERLAND and SINGAPORE) Fig. 11-67.

The timing data (referring to the 1 mm lift of the points) are as follows: Intake: open 23°30' before TDC close 57°30' after BDC Exhaust: open 49°30' before BDC close 12°30' after TDC

Functioning clearance with a cold engine:

intake valves 0.10 mm exhaust valves 0.15 mm

11-67

1 = Intake start before TDC 2 = End of exhaust after TDC 3 = Exhaust start before BDC 4 = Intake end after BDC

22°30

28°30

63°30

69°30

11-68

CAMSHAFT AND LUBRICATION SYSTEM ASSEMBLY

DAYTON RS (excluding the version with specifications for USA. SWITZERLAND and SINGAPORE) Fig. 11-68.

The timing data (referring to the 1 mm lift of the points) are as follows: Intake: open 23°30' before TDC close 69°30' after BDC Exhaust: open 63°30' before BDC close 28°30' after TDC Functioning clearance with a cold engine: intake valves 0.10 mm exhaust valves 0.15 mm

11-69

ROCKER ARM SUPPORT

TAPPET

13.982÷14.000

Ø14.017÷14.006

0,030

11-70 11-71

48.8÷49.2

CAM SHAFT HOUSING CAM SHAFT

Ø38.000÷38.025

INTAKE

EXHAUST

Ø24.967÷24.980

25.000÷25.021

IDENTIFICATION CODE S = left

D = right

11-72

SERVICE SHAFT HOUSING

Ø32.025÷32.050

SERVICE SHAFT

SPRING SET CHECKING

Ø46.984÷47.000

Ø47.025÷47.050

11-73

Ø32.000÷32.016

11-74

NOTE: The Data in square brackets refer to the Model DAYTONA RS except for Models with

specifications for USA. SWITZERLAND and SINGAPORE - Fig. 11-75

When the valve seats on the heads have been milled it is necessary, after fitting the valves on the heads, to check that the springs are compressed between 36.5 ÷37.5 mm [36 ÷ 36,5]; to obtain this value insert «A» washers of appropriate thicknesses (these are supplied in thicknesses of 1 mm and 1.5 mm).

36.5÷37.5

11-75

INSPECTION OF VALVE SPRINGS - Fig. 11-76

Check that the springs are not deformed and have not lost their load:

External spring

■ free, has a length of 43.5;

■ with closed valve, has a length of 36 mm and must give a load of 16.42÷18.14 kg;

■ with open valve, has a length of 26.5 mm and must give a load of 38.02÷40.37;

■ compressed, has a length of 22.5 mm.

Internal spring

■ free, has a length of 37 mm;

■ with closed valve, has a length of 32 mm and must give a load of 9.41÷10.39;

■ with open valve, has a length of 22.5 mm and must give a load of 27.86÷29.59;

■ compressed, has a length of 20.3 mm.

If the springs do not satisfy the above specifications they must be replaced.

Kg 16,42÷8,14

Kg 38,02÷40,37

43,5 mm

Kg 9,41÷10,39

Kg 27,86÷29,59

37 mm

36 mm

26,5 mm

32 mm

22,5 mm

11-76

Cylinder wear check - Fig. 11-77

Ø 90.000÷90.018

1st Measurement

89.967÷89.985

2nd Measurement

control measurement

3rd Measurement

for selection

Grading cylinder diameter Grading pistons diameter

GRADE A GRADE B GRADE C

89,967÷89,973 89,973÷89,979 89,979÷89,985

GRADE A GRADE B GRADE C

89,967÷89,973 89,973÷89,979 89,979÷89,985

11-77

NOTE: The «A», «B», «C» grade cylinders must be coupled with the corresponding pistons in the

grades «A», «B», «C».

The grading measurements indicated in the tables must be taken at 24 mm from the lower edge of the piston, at right-angles to the gudgeon pin axis.

Maximum cylinder ovalization allowed: ................................................................................................0.02 mm.

Maximum clearance allowed between cylinder and piston: .................................................................0.08 mm.

PISTONS

1.52÷1.54

3.02÷3.04

22.000÷22.006

Coupling data

Dia. Dia.

PISTON PIN PISTON HOLES PISTON PIN & HOLES

mm mm ON PISTON mm

21,994 22,000

CLEARANCE BETWEEN

0,012÷0,002

21,998 22,006

OIL SCRAPER COMPRESSION RINGS

Each piston is fitted with: 1 upper piston ring, 1 intermediate slotted piston ring, 1 oil control ring.

2.975÷2.990

Ø22

Ø90

58÷0.1

-0.006

-0.002

1.475÷1.490

0.40÷0.65

0,30÷0,60

11-78

Aperture between the ends of the piston rings fitted on the piston

Upper compression ring

and slotted ring:................................0.40-0.65 mm

oil control ring:..................................0.30-0.60 mm

Fitting of the piston in the little-end bearing.

When the piston is fitted in the little-end bearing, the part marked in the figure with the arrow «A» must be turned towards the exhaust manifold.

11-79

CONNECTING RODS

When overhauling the connecting rods, carry out the following checks:

■ the condition of the bushings and the clearance

between these and the gudgeon pins;

■ parallelism of the axes;

■ connecting rod bearings.

The bearings are of the thin shell type, in babbitt alloy that cannot be adjusted; if there are any traces of seizing or wear they must be replaced. If the bearings are replaced it may be necessary to mill the crankshaft pin. Before grinding the crankshaft pin, it is advisable to measure the pin diameter in correspondence to the maximum wear (Fig. 11-81); this is to establish to which undersize class the bearing should belong and to what diameter the pin should be ground.

Thicknesses of the connecting rod bearings

CARRILLO connecting rods

22.0023

22.0026

23.825

23.775

139,985 ÷ 140,015

NORMAL BEARING

(PRODUCTION) mm

bearings for connecting rod pin

dia. undersized by mm

0,254 0,508 0,762

from 1,535 1,662 1,789 1,916 to 1,544 1,671 1,798 1,925

1.535 ÷ 1.544

47.130

47.142

4.44 ÷ 4.57

19.95 ÷ 19.20

47.0135

47.0132

23.825

23.775

11-80

CRANKSHAFT PIN DIAMETER:

STANDARD DIA. UNDER SIZED 0.254 mm UNDER SIZED 0.508 mm UNDER SIZED 0.762 mm

44,008÷44,012 43,754÷43,758 43,500÷43,504 43,246÷43,250

Gudgeon pin and bushing coupling data

INTERNAL DIA. OF CLEARANCE BETWEEN

PRESSED AND GUDGEON PIN

MACHINED mm AND BUSHING mm

GUDGEON PIN DIA.

22,0023 21,994 22,0026 21,998

11-80/A

0,25÷0,32

11-81

Check parallelism of the axes.

// 0.10 X Y

200

two axes of the little-end and the big end measured at the distance of 200 mm must be ±0.10 mm.

FITTING OF THE CONNECTING RODS ON THE DRIVE SHAFT

Torque loading screw Kgm 8,5 ÷ 9,3

Note: Accurately determine the parallelism of axes X-X/Y-Y = 0,100 over 200 mm

The assembly clearance between the bearing and the connecting rod pin ranges from a minimum of

0.022 mm to a maximum of 0.064 mm. The clearance between the connecting rod shim adjustment and those of the crankshaft is 0.30÷0.50

11-82

mm. Fit the connecting rods on the crankshaft, tighten the nuts on the caps with a dynamometric wrench using a tightening torque of 8,5÷9,3 kgm.

CRANKSHAFT

■ between main bearing and journal timing side 0.028÷0.060 mm

■ between main bearing and journal flywheel side 0.040÷0.075;

■ between bearing and connecting rod pin 0.022÷0.064 mm.

When grinding the crankshaft journals it is necessary to maintain the value of the connecting throw on the shoulders that is: 2÷2.5 mm for the connecting rod pin, 3 mm for the main journal on the flywheel side and 1.5÷1.8 mm for the main journal on the timing system side.

Diameter of main journal on flywheel side Diameter of main journal on timing system side

NORMAL UNDERSIZED BY mm

PRODUCTION

0.2 0.4 0.6

53.970 53.770 53.570 53.370

53.951 53.751 53.551 53.351

NORMAL UNDERSIZED BY mm

PRODUCTION

0.2 0.4 0.6

37.975 37.775 37.575 37.375

37.959 37.759 37.559 37.359

11-83

WEIGHT CHECK FOR CRANKSHAFT BALANCING

The connecting rods complete with nuts and bolts must have a balanced weight. There is a tolerance of 4 grams. For a static balancing of the crankshaft, the pin must bear a weight of Kg. 1558±3.

Ø54.000÷54.019

Ø53.970÷53.951

53.800÷53.819 M 2

53.600÷53.619 M 4

53.400÷53.419 M 6

0.6 0.4 0.2

Internal dia. of main bearing for spare parts Identification code

Undersizianf g by mm

Ø44.008÷44.12

48.000÷48.100

CRANKSHAFT COUPLING CLEARANCE

= m/m 0,040÷0,075

Ø37.959÷37.975

38.969÷39.031

37.800÷37.816 M 2

37.600÷37.616 M 4

37.400÷37.416 M 6

CRANKSHAFT COUPLING CLEARANCE

= m/m 0,028÷0,060

Internal dia. of main bearing for spare parts Identification code

0.6 0.4 0.2

Undersizianf g by mm

Ø38.000÷38.016

CHECK CRANKCASE (FLYWHEEL FLANGE SIDE) FOR OIL LEAKS

In the event of oil leaks from the rear part of the crankcase (flywheel area), check the following:

■ that the seal ring on the flange on the flywheel side is not damaged;

■ that there is no blowing in the crankcase. To make this check, rest the engine on a bench with the flywheel side

uppermost, after removing the flywheel from the crankshaft;

■ fill the upper part of the crankcase with water;

■ blow through the breather pipe with low pressure compressed air (to avoid dislodging the oil seals), taking care

to hold the seal ring with two fingers;

■ if there are leaks, bubbles should appear. In this case the porosity must be filled with a suitable commercial

compound.

11-84

OIL PRESSURE TRANSMITTER

CHECK OIL PRESSURE TRANSMITTER (Fig. 11-85)

To check the efficiency of the transmitter, mounted it on the special tool equipped with a pressure gauge; connect the positive lead (+) of the tester to the transmitter and the negative lead (–) to earth, then blow compressed air through the coupling of the above tool, making sure that the indicator on the tester moves when the pressure (looking at the gauge) reaches 0.15÷0.35 kg/sq.cm.

11-85

ENGINE OIL PRESSURE ADJUSTMENT VALVE (Fig. 11-86 / 11-87 / 11-88)

Check the oil pressure valve calibration. The oil pressure adjustment valve «A» is screwed to the oil sump. It must be calibrated to allow a pressure in the delivery circuit of 5 kg/sq.cm. To test the calibration, it is necessary to fit the valve on the appropriate tool with a gauge fitted; blow compressed air through the tool coupling and make sure that the valve opens precisely at the set pressure. If the valve opens at a lower pressure, place one or more «B» washers under the spring; if it opens at a higher pressure, reduce the number of «B» washers or increase the number of «C» washers as appropriate.

11-86

11-87

11-88

THERMOSTATIC VALVE (Fig.11-89)

The thermostatic valve opens the oil passage to the radiator when the temperature exceeds 71°c.

Bulb characteristic

Stroke mm

Temperature °C

Opening start

OIL PUMP

20.980÷20.993

11-89

Nut: Loctite mounted

Tightening torque

kgm 1.5 ~ 1.8

36.000

Ø11.983÷11.994

11-9111-90

20.067÷21

Ø10.013÷10.035

Ø12.000÷12.018

37.000÷37.010

21.040÷21.073

11-92 11-93

9.085÷10

Moto Guzzi Daytona 1100 sport User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual