Moto Guzzi Engine V1100 1949-2008 Manual de reparatie
00/2005-10
Engine V1100
UK
UK
Cod. 8140898
Cod.
workshopmanual
Engine V1100
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INTRODUCTION
INTRODUCTION 0
0-1
INTRODUCTION
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Engine V1100
SUMMARY
0.1. INTRODUCTION .............................................................................................................................................. 3
0.1.1. FOREWORD ............................................................................................................................................. 3
0.1.2. REFERENCE MANUALS .......................................................................................................................... 4
0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS ........................................................................................ 5
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INTRODUCTION
0.1. INTRODUCTION
0.1.1. FOREWORD
This manual provides the information required for normal servicing.
This publication is intended for use by Moto Guzzi Dealers and their qualified mechanics; many concepts have been
omitted on purpose as their inclusion would be superfluous. Since complete mechanical explanations have not been
included in this manual, the reader must be familiar with basic notions of mechanics, as well as with basic repair
procedures. Without such familiarity, repairs and checks could be ineffective and even hazardous. Since the repair and
vehicle check instructions are not exhaustive, special care must be taken to avoid damage and injury. Moto Guzzi s.p.a.
undertakes to constantly improve the design of its products and their literature to ensure that the customer is satisfied of
the product. The main technical modifications and changes in repair procedures are communicated to all Moto Guzzi
dealers and agencies world-wide. Such modifications will be entered in subsequent editions of the manual. Should you
need assistance or clarifications about the inspection and repair procedures, please contact the Moto Guzzi SERVICE
DEPT., they will be glad to give you any information on the matter, or supply you with any detail on updates and technical
changes applied to the vehicle.
Moto Guzzi s.p.a. reserves the right to make changes to its products at any time, barring any such changes as may alter
the essential features of a product as specified in the relevant manual.
All rights of storage using electronic means, reproduction and total or partial adaptation, whatever the means adopted,
are reserved in all countries.
Third parties' products are only mentioned for information purposes, and constitute no engagement.
Moto Guzzi s.p.a. is not liable in any way for the performance or use of these products.
For further details, see (REFERENCE MANUALS).
First edition: October 2005
Produced and printed by:
VALLEY FORGE DECA
Ravenna, Modena, Torino
DECA S.r.l.
Registered Office and Administrative Headquarter
via Vincenzo Giardini, 11 - 48022 Lugo (RA) - Italy
Tel. +39 - 0545 216611
Fax +39 - 0545 216610
E-mail: deca@vftis.spx.com
www.vftis.com
On behalf of:
Moto Guzzi s.p.a.
via E.V. Parodi, 57- 23826 Mandello del Lario (Lecco) - Italy
Tel. +39 – 0341 - 709111
Fax +39 – 0341 - 709220
www.motoguzzi.it
www.servicemotoguzzi.com
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INTRODUCTION
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0.1.2. REFERENCE MANUALS
PARTS CATALOGUES
guzzi part# (description)
GU077_00
OWNER'S MANUALS
guzzi part# (description)
05.90.00.30
05.90.00.31
CHASSIS WORKSHOP MANUAL
guzzi part# (description)
8140856
8140857
8140858
8140859
8140860
8140861
8CM0077
8CM0078
ENGINE WORKSHOP MANUAL
guzzi part# (description)
8140894
8140895
8140896
8140897
8140898
8140899
CD FOR THE NETWORK
guzzi part# (description)
8CM0093
8CM0094
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0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS
# = number
< = less than
> = greater than
≤ = less than or equal to
≥ = more than or equal to
~ = approximately
∞ = infinity
°C = degrees Celsius (centigrade)
°F = degrees Fahrenheit
± = plus or minus
a.c = alternating current
A = Ampere
Ah = Ampere per hour
API = American Petroleum Institute
AT = high voltage
AV/DC = Anti-Vibration Double Countershaft
bar = pressure measurement (1 bar = 100 kPa)
d.c. = direct current
cc = cubic centimetres
CO = carbon monoxide
CPU = Central Processing Unit
DIN = German industrial standards (Deutsche Industrie Norm)
DOHC = Double Overhead Camshaft
ECU = Electronic Control Unit
rpm = revolutions per minute
HC = unburnt hydrocarbons
ISC = Idle Speed Control
ISO = International Standardisation Organisation
kg = kilograms
kgm = kilogram metre (1 kgm = 10 Nm)
km = kilometres
km/h = kilometres per hour
kΩ = kilo Ohm
kPa = kiloPascal (1 kPa = 0.01 bar)
KS = clutch side (from the German "Kupplungsseite")
kW = kilowatt
l = litres
LAP = racetrack lap
LED = Light Emitting Diode
LEFT SIDE = left side
m/s = metres per second
max = maximum
mbar = millibar (1 mbar = 0.1 kPa)
mi = miles
MIN = minimum
MPH = miles per hour
MS = flywheel side (from the German "Magnetoseite")
MΩ = MegaOhm
N.A. = Not Available
N.O.M.M. = Motor Octane Number
N.O.R.M. = Research Octane Number
Nm = Newton metre (1 Nm = 0.1 kgm)
Ω = ohm
PICK-UP = pick-up
BDC = Bottom Dead Centre
TDC = Top Dead Centre
PPC = Pneumatic Power Clutch
RIGHT SIDE = right side
SAE = Society of Automotive Engineers
SAS = Secondary Air System
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TEST = diagnostic check
T.B.E.I. = crown-head Allen screw
T.C.E.I. = cheese-head Allen screw
T.E. = hexagonal head
T.P. = flat head screw
TSI = Twin Spark Ignition
UPSIDEDOWN = inverted fork
V = volt
W = watt
Ø = diameter
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GENERAL INFORMATION
GENERAL INFORMATION 1
1-1
GENERAL INFORMATION
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Engine V1100
SUMMARY
1.1. STRUCTURE OF THE MANUAL...................................................................................................................... 3
1.1.1. CONVENTIONS USED IN THE MANUAL ................................................................................................. 3
1.1.2. SAFETY WARNINGS ................................................................................................................................ 4
1.2. GENERAL RULES............................................................................................................................................ 5
1.2.1. BASIC SAFETY RULES ............................................................................................................................ 5
1.3. DANGEROUS ELEMENTS............................................................................................................................... 8
1.3.1. WARNINGS ............................................................................................................................................... 8
1.4. RUNNING-IN .................................................................................................................................................. 11
1.4.1. RUNNING-IN ........................................................................................................................................... 11
1.5. POSITION OF THE SERIAL NUMBERS ........................................................................................................ 12
1.5.1. POSITION OF THE SERIAL NUMBERS................................................................................................. 12
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GENERAL INFORMATION
1.1. STRUCTURE OF THE MANUAL
1.1.1. CONVENTIONS USED IN THE MANUAL
• This manual is divided in sections and subsections, each covering a set of the most significant components. Refer
to the index of sections when consulting the manual.
• Unless expressly specified otherwise, assemblies are reassembled by reversing the dismantling procedure.
• The terms "right" and "left" are referred to the rider seated on the vehicle in the normal riding position.
• Motorcycle operation and basic maintenance are covered in the "OWNER'S MANUAL".
In this manual any variants are identified with these symbols:
optional
catalytic version
- all versions
MP national certification
SF European certification (EURO 1 limits)
VERSION:
Italy
United
Kingdom
Austria
Portugal
Finland
Belgium
Germany
France
Spain
Greece
Holland
Switzerland
Denmark
Japan
Singapore
Slovenia
Israel
South Korea
Malaysia
Chile
Croatia
Australia
United States of America
Brazil
South Africa
New Zealand
Canada
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1.1.2. SAFETY WARNINGS
The symbols and warnings used throughout this manual have the following meanings:
Safety warning. This symbol appears, whether in the manual or on the vehicle itself, to indicate a
personal injury hazard. Non-compliance with the indications given in the messages preceded by this
symbol may result in serious risks for your and other people’s safety and for the vehicle!
DANGER
Indicates a potential hazard which may result in serious injury or even death.
WARNING
Indicates a potential hazard which may result in minor personal injury or damage to the vehicle.
NOTE The word "NOTE" in this manual identifies important information or instructions.
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GENERAL INFORMATION
1.2. GENERAL RULES
1.2.1. BASIC SAFETY RULES
CARBON MONOXIDE
Should it be necessary to perform some operations with the vehicle running, make sure to work outdoors or in a wellaerated room.
Avoid starting the engine indoors.
In case you are working indoors, use a gas exhaust system.
DANGER
Exhaust gases contain carbon monoxide, which is extremely toxic if inhaled and may cause loss of
consciousness or even lead to death.
FUEL
DANGER
The fuel used to operate engines is highly flammable and becomes explosive under particular
conditions.
Refuelling and engine servicing should take place in a well-ventilated area with the engine stopped.
Do not smoke when refuelling or in the proximity of sources of fuel vapours, avoid flames, sparks and
any element that could ignite fuel or provoke explosions.
DO NOT DISPOSE OF FUEL IN THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
HIGH-TEMPERATURE COMPONENTS
The engine and the components of the exhaust system become very hot and remain hot for some time after the engine
has been stopped.
Before handling these components, wear insulating gloves or wait until the engine and the exhaust system have cooled
down.
USED GEARBOX AND FORK FLUIDS
DANGER
Wear latex gloves when servicing.
Gearbox fluid may cause serious damage to the skin if handled daily and for long periods.
Wash your hands carefully after use.
Take it to the filling station where you usually buy it or to an oil salvage centre.
Wear latex gloves when servicing.
DO NOT DISPOSE OF FLUID IN THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
BRAKE FLUID
WARNING
When handling the brake fluid, take care not to spill it on the plastic, rubber or painted parts, since it
can damage them. When carrying out the maintenance operations on the braking system, use a clean
cloth to cover these parts.
Always wear safety goggles when working on the braking system.
The brake fluid is highly irritant. Avoid contact with your eyes.
If the brake fluid gets in contact with your eyes, carefully wash them with fresh water and immediately
seek medical advice.
KEEP AWAY FROM CHILDREN.
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GENERAL INFORMATION
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HYDROGEN AND BATTERY FLUID
DANGER
The battery electrolyte is a toxic, caustic substance containing sulphuric acid and thus able to cause
severe burns in case of contact with the skin.
Always wear tight gloves and protective clothes when handling this fluid.
In case of contact with skin, rinse with plenty of fresh water.
Always use a protection for your eyes since even a very small amount of the battery fluid can cause
blindness. In the event of contact with your eyes, carefully wash them with water for fifteen minutes
and then consult immediately an eye specialist.
Should you accidentally drink some fluid, drink abundant water or milk, then drink magnesia milk or
vegetable oil and immediately seek medical advice.
The battery gives off explosive gases and must be kept away from flames and sources of ignition or
heat; do not smoke near the battery.
Make sure the room is well-aerated when servicing or recharging the battery.
KEEP AWAY FROM CHILDREN.
The battery fluid is corrosive.
Do not spill it, especially on plastic parts.
Make sure that the electrolyte acid is suitable for the type of battery used.
GENERAL PRECAUTIONS AND INFORMATION
Follow these instructions closely when repairing, disassembling or reassembling the motorcycle or its components.
DANGER
Using bare flames is strictly forbidden when working on the motorcycle. Before servicing or
inspecting the motorcycle: stop the engine and remove the key from the ignition switch; allow for the
engine and exhaust system to cool down; where possible, lift the motorcycle using adequate
equipment placed on firm and level ground. Be careful of any parts of the engine or exhaust system
which may still be hot to the touch to avoid scalds or burns.
Do not put any vehicle parts into your mouth: vehicle components are not edible and some of them
are harmful or even toxic.
Unless expressly specified otherwise, assemblies are reassembled by reversing the dismantling
procedure. Where a procedure is cross-referred to relevant sections in the manual, proceed sensibly
to avoid disturbing any parts unless strictly necessary. Do not polish matt-painted surfaces with
polishing paste.
Never use fuel instead of solvent to clean the motorcycle.
Do not clean any rubber or plastic parts or the seat with alcohol, petrol or solvents. Clean with water
and mild detergent.
Always disconnect the battery negative (-) lead before soldering any electrical components.
When two or more persons service the same motorcycle together, special care must be taken to avoid
personal injury.
For further warnings, see (DANGEROUS ELEMENTS)
BEFORE DISASSEMBLING ANY COMPONENTS
• Clean off all dirt, mud, and dust and clear any foreign objects from the vehicle before disassembling any
components.
• Use the model-specific special tools where specified.
DISASSEMBLING THE COMPONENTS
- Never use pliers or similar tools to slacken and/or tighten nuts and bolts. Always use the suitable spanner.
- Mark all connections (hoses, wiring, etc.) with their positions before disconnecting them. Identify each connection
using a distinctive symbol or convention.
- Mark each part clearly to avoid confusion when refitting.
- Thoroughly clean and wash any components you have removed using a detergent with low flash point.
- Mated parts should always be refitted together. These parts will have seated themselves against one another in
service as a result of normal wear and tear and should never be mixed up with other similar parts on refitting.
- Certain components are matched-pair parts and should always be replaced as a set.
- Keep away from heat sources.
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GENERAL INFORMATION
REASSEMBLING THE COMPONENTS
DANGER
Never reuse a circlip or snap ring. These parts must always be renewed once they have been
disturbed.
When fitting a new circlip or snap ring, take care to move the open ends apart just enough to allow
fitment to the shaft.
Make it a rule to check that a newly-fitted circlip or snap ring has located fully into its groove.
Never clean a bearing with compressed air.
NOTE All bearings must rotate freely with no hard spots or noise. Replace any bearings that do not meet these
requirements.
- Use GENUINE Moto Guzzi spare parts only.
- Use the specified lubricants and consumables.
- Where possible, lubricate a part before assembly.
- When tightening nuts and bolts, start with the largest or innermost nut/bolt and observe a cross pattern. Tighten
evenly, in subsequent steps until achieving the specified torque.
- Replace any self-locking nuts, gaskets, seals, circlips or snap rings, O-rings, split pins, bolts and screws which have
a damaged thread.
- Lubricate the bearings abundantly before assembly.
- Make it a rule to check that all components you have fitted are correctly in place.
- After repairing the motorcycle and after each service inspection, perform the preliminary checks, and then test ride
the motorcycle in a private estate area or in a safe area away from traffic.
- Clean all mating surfaces, oil seal edges and gaskets before assembly. Apply a thin layer of lithium grease along the
edges of oil seals. Fit oil seals and bearings with the marking or serial number facing outwards (in view).
ELECTRICAL CONNECTORS
To disconnect the electrical connectors, follow the procedures below. Failure to comply with these procedures may lead
to irreparable damage to the connector and the wiring as well.
If present, press the special safety hooks.
WARNING
• Grasp the two connectors and disconnect them by pulling them in the two opposite directions.
• In case of dirt, rust, moisture, etc.., thoroughly clean the inside of the connectors with compressed air.
• Make sure that the cables are correctly fitted inside the connector terminals.
NOTE The two connectors have just one correct positioning. Make sure to position them in the right direction.
• Then fit the two connectors. Make sure they are correctly coupled (a click will be heard if hooks are present).
TIGHTENING TORQUE SETTINGS
Do not pull cables to disconnect the two connectors.
DANGER
Always remember that the tightening torque settings of all wheel, brake, wheel shaft and other
suspension parts fasteners play a fundamental role to ensure vehicle safety. Make sure that these
values are always within the specified limits.
Check fastening parts tightening torque settings at regular intervals. Upon reassembly, always use a
torque wrench.
Failure to comply with these recommendations could lead to the loosening and detachment of one of
these parts with a consequent locking of the wheel or other serious troubles affecting the vehicle
manoeuvrability, and thus the risk of falls and serious injuries or death.
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1.3. DANGEROUS ELEMENTS
1.3.1. WARNINGS
FUEL
DANGER
The fuel used to operate engines is highly flammable and becomes explosive under particular
conditions.
Refuelling and engine servicing should take place in a well-ventilated area with the engine stopped.
Do not smoke when refuelling or in the proximity of sources of fuel vapours, avoid flames, sparks and
any element that could ignite fuel or provoke explosions.
Take care not to spill fuel out of the filler, or it may ignite when in contact with hot engine parts.
In the event of accidental fuel spillage, make sure the affected area is fully dry before starting the
engine. Fuel expands from heat and when left under direct sunlight.
Never fill the fuel tank up to the brim. Tighten the filler cap securely after each refuelling.
Avoid contact with skin. Do not inhale vapours. Do not swallow fuel. Do not transfer fuel between
different containers using a hose.
DO NOT DISPOSE OF FUEL IN THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
Use only premium grade unleaded petrol, min. O.N. 95 (RON) and 85 (MON).
LUBRICANTS
DANGER
A good lubrication ensures the vehicle safety.
Failure to keep the lubricants at the recommended level or the use of a non-suitable new and clean
type of lubricant can lead to the engine or gearbox seizure, thus causing serious accidents, personal
injury or even death.
Gearbox fluid may cause serious damage to the skin if handled daily and for long periods.
Wash your hands carefully after use.
Do not dispose of oil in the environment.
Take it to the filling station where you usually buy it or to an oil salvage centre.
WARNING
When filling the vehicle with this oil, take care not to spill it out. Immediately clean spilt oil, or it might
damage the vehicle paintwork.
In case of contact with oil, the tyre surface will become very slippery, thus becoming a serious danger
for your safety.
In case of leaks, do not use the vehicle. Check and trace the cause of leaks and proceed to repair.
ENGINE OIL
DANGER
Engine oil may cause serious damage to the skin if handled daily and for long periods.
Wash your hands carefully after use.
Do not dispose of oil in the environment.
Dispose of engine oil through the nearest waste oil reclamation firm or through the supplier.
Wear latex gloves when servicing.
FRONT FORK FLUID
DANGER
Front suspension response can be modified to a certain extent by changing damping settings and/or
selecting a particular grade of oil. Standard oil: SAE 20 W. Choose suitable viscosity grades according
to the desired set-up (choose SAE 5W for a softer suspension, 20W for a stiffer suspension).
The two grades can also be mixed in varying solutions to obtain the desired response.
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GENERAL INFORMATION
BRAKE FLUID
NOTE This vehicle is fitted with front and rear disc brakes. Each braking system is operated by an independent hydraulic
circuit. The information provided below applies to both braking systems.
DANGER
Do not use the vehicle in case brakes are worn out or do not work properly. The brakes are the parts
that most ensure your safety and for this reason they must always be perfectly working. Failure to
comply with these recommendations will probably lead to a crash or an accident, with a consequent
risk of personal injury or death.
A wet surface reduces brakes efficiency.
DANGER
In case of wet ground the braking distance will be doubled, since both brakes and tyre grip on the
road surface are extremely reduced by the water present on the road surface.
Any water on brakes, after washing the vehicle or driving on a wet road surface or crossing puddles
or gips, can wet brakes so as to greatly reduce their efficiency.
Failure to comply with these recommendations may lead to serious accidents, with a consequent risk
of severe personal injuries or death.
Brakes are critical safety components. Do not ride the vehicle in case brakes are not working at their
best.
Check for brakes proper operation before every trip.
Brake fluid is an irritant. Avoid contact with eyes or skin.
In the event of accidental contact, wash affected body parts thoroughly. In the event of accidental
contact with eyes, contact an eye specialist or seek medical advice.
DO NOT RELEASE BRAKE FLUID INTO THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
When handling brake fluid, take care not to spill it onto plastic or paint-finished parts or they will
damage.
DANGER
Do not use any brake fluids other than the specified type. Never mix different types of fluids to top up
level, as this will damage the braking system.
Do not use brake fluid from containers which have been kept open or in storage for long periods.
Any sudden changes in play or hardness in the brake levers are warning signs of problems with the
hydraulic circuits.
Ensure that the brake discs and brake linings have not become contaminated with oil or grease. This
is particularly important after servicing or inspections.
Make sure the brake lines are not twisted or worn.
Prevent accidental entering of water or dust into the circuit.
Wear latex gloves when servicing the hydraulic circuit.
DISC BRAKES
DANGER
The brakes are the parts that most ensure your safety and for this reason they must always be
perfectly working; check them before every trip.
A dirty disc soils the pads.
Dirty pads must be replaced, while dirty discs must be cleaned with a high-quality degreaser.
Perform the maintenance operations with half the indicated frequency if the vehicle is used in rainy or
dusty areas, on uneven surfaces or for racing.
Check brake pads for wear.
When the brake pads wear out, the level of the fluid decreases to automatically compensate for their
wear.
The front brake fluid reservoir is located on the right handlebar, near the front brake lever.
The rear brake fluid reservoir is located under the right fairing.
Do not use the vehicle if the braking system leaks fluid.
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TYRES
WARNING
If tyres are excessively inflated, the vehicle will be hard, difficult and uncomfortable to ride.
In addition, the roadworthiness, mainly on wet surfaces and during cornering, will be impaired.
Flat tyres (insufficient pressure) can slip on the rim and make you lose the control of the vehicle.
In this case too, both vehicle roadworthiness, manoeuvrability and brake efficiency will be impaired.
Tyres changing, repair, maintenance and balancing must be carried out by specialised technicians
using suitable equipment.
When new, tyres can have a thin slippery protective coating. Drive carefully for the first kilometres
(miles).
Never use rubber treating substances on tyres.
In particular, avoid contact with fluid fuels, leading to a rapid wear.
In case of contact with oil or fuel, do not clean but change the tyres.
DANGER
Some of the factory-assembled tyres of this vehicle are provided with wear indicators.
There are several kinds of wear indicators.
For more information on how to check the wear, contact your Dealer.
Visually check if the tyres are worn and in this case have them changed.
If a tyre deflates while driving, stop immediately.
Avoid hard brakings or moves and do not close throttles too abruptly.
Slowly close the throttle grip, move to the edge of the road and use the engine brake to slow down
until coming to a halt.
Failure to comply with these recommendations may lead to accidents, with a consequent risk of
personal injuries or death.
Do not install tyres with air tube on rims for tubeless tyres and vice versa.
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GENERAL INFORMATION
1.4. RUNNING-IN
1.4.1. RUNNING-IN
Correct engine running-is essential to ensuring proper performance and durability.
Twisty, hilly roads are ideal for an effective running-in of engine, suspension and brakes.
During running-in, change speed.
This will allow engine parts to be alternately loaded and unloaded, allowing them to cool down when unloaded.
While it is important to put some stress on engine components during running-in, it is equally important to avoid extreme
load conditions.
WARNING
Only after the first 2000 km (1243 mi) of running-in is it possible to obtain the best acceleration
performance from the vehicle.
Follow these recommendations:
• Do not open the throttle completely if the speed is low, both during and after running-in.
• Until you have covered the first 100 km (62 mi), use the brakes gently and avoid harsh, prolonged braking. This
ensures a correct bedding-in of the pads on the brake discs.
• During the first 1000 km (621 mi), never exceed 5000 rpm (see table).
WARNING
After the first 1000 km (621 mi), carry out the checking operations indicated in the column "After
running-in", see REGULAR SERVICE INTERVALS CHART, in order to avoid hurting yourself or other
people and/or damaging the vehicle.
• After the first 1000 km (621 mi) and until covering 2000 km (1243 mi), drive more briskly, varying speed and using
maximum acceleration for just a few seconds, in order to ensure better coupling of the components; never exceed
6000 rpm (see table).
• After the first 2000 km (1243 mi) you may run the engine harder, however, without exceeding the maximum rpm
allowed (7600 rpm).
Recommended maximum rpm
Mileage Km (mi) rpm
0÷1000 (621) 5000
1000÷2000 (621÷1243) 6000
Over 2000 (1243) 7600
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1.5. POSITION OF THE SERIAL NUMBERS
1.5.1. POSITION OF THE SERIAL NUMBERS
These numbers are necessary for the registration of the
vehicle.
NOTE Do not alter the identification numbers if you do not
want to incur severe penal and administrative sanctions; in
particular, altering the frame number voids the warranty.
ENGINE NUMBER
The engine number is stamped on the left side, close to
engine oil level plug.
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TECHNICAL INFORMATION
TECHNICAL INFORMATION 2
2-1
TECHNICAL INFORMATION
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Engine V1100
SUMMARY
2.1. TECHNICAL INFORMATION............................................................................................................................ 3
2.1.1. TECHNICAL DATA.................................................................................................................................... 3
2.1.2. LUBRICANT TABLE .................................................................................................................................. 4
2.1.3. TIGHTENING TORQUE SETTINGS ......................................................................................................... 5
2.1.4. SPECIAL TOOLS ...................................................................................................................................... 7
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TECHNICAL INFORMATION
2.1. TECHNICAL INFORMATION
2.1.1. TECHNICAL DATA
ENGINE
Type twin-cylinder, 90° V transversal, 4-stroke engine
Number of cylinders two
Cylinder arrangement V, 90°
Total displacement 1064 cu cm (65 cu in)
Bore/stroke 92 x 80 mm (3.6 x 3.1 in).
Compression ratio 9.6 : 1
Starting electric
Engine idling speed 1100 ± 100 rpm
Clutch single plate, dry clutch with cush drive damper
Lubricating system System under pressure, adjustment by valves and vane pump
Air filter cartridge, dry
Cooling system air cooled
CAPACITIES
Engine oil Engine oil and oil filter change 3600 cu. cm (219 cu in)
Gearbox fluid 500 cu cm (30.5 cu in)
Transmission fluid 380 cu cm (23.2 cu in)
TIMING SYSTEM
Timing diagram: 2 valves, with rods and rocker arms
Values with inspection clearance between
rocker arms and valve
TRANSMISSION SYSTEM
primary drive gear, ratio: 26/35 = 1:1.3461
gearbox Mechanic, with 6 speeds, controlled by a pedal on engine left side
overall gear ratios:
1st gear 17/38 = 1:2.2353
2nd gear 20/34 = 1:1.7
3rd gear 23/31 = 1:1.3478
4th gear 26/29 = 1:1.1154
5th gear 31/30 = 1:0.9677
final drive with cardan joint
ratio 12/44 = 1:3.6667
FUEL SYSTEM
Type Electronic injection (Weber – Marelli) with stepper motor
Choke Ø 36 mm (1.417 in.)
Fuel Premium grade unleaded petrol, minimum octane rating 95 (RON) and
SPARK PLUGS
Internal (long life) NGK PMR8B
External NGK BPR6ES
Electrode gap 0.6 – 0.7 mm (0.024 – 0.028 in.)
intake 0.10 mm (0.0039 in.)
exhaust 0.15 mm (0.0059 in.)
85 (MON).
2-3
TECHNICAL INFORMATION
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2.1.2. LUBRICANT TABLE
LUBRICANT PRODUCT
Engine oil
Transmission fluid
Gearbox fluid
Bearings and other
lubrication points
RECOMMENDED:
As an alternative to recommended oils, top brand oils meeting or exceeding
CCMC G-4 A.P.I. SG specifications can be used.
RECOMMENDED:
RECOMMENDED:
RECOMMENDED:
GREASE SM2.
As an alternative to recommended grease, use top brand rolling bearing
grease that will resist a temperature range of -30°C to +140°C (-22°F to
+284°F), with dripping point 150°C to 230°C (302°F to 446°F), high
corrosion protection, good resistance to water and oxidisation.
Engine V1100
RACING 4T 5 W 40
TRUCK GEAR 80 W 90
ROTRA MP/S 85 W 90
BIMOL GREASE 481, AUTOGREASE MP or
2 - 4
Engine V1100
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2.1.3. TIGHTENING TORQUE SETTINGS
TECHNICAL INFORMATION
DESCRIPTION
QUANTITY
HEAD UNIT
head taper cap 6 4
stud bolt M8x42 4 M8 35
adjuster 4 / / /
Nut 4 8-11
Hex.head screw DA M6x16 4 M6 6-8
stainl.st. TBEI screw M6x25 16 M6 10
stainl.st.flanged TBEI screw M5x16 4 M5 6-7
oil/head temperature sensor M12x1.5 1 M12 10-12
head temperature sensor casing M10x1.5 1 M10 10-12
TIMING UNIT
Hex.head screw DA M6x20 3 M6 8-12
nut M18x1.5 1 M18 150
belt tension 50
LOCKS
stud bolt M10x35 2 M10 40
Linkage 1 42
nut EA ZB M10x1.5 2 M10 40-42
head bolt 1 40-42
stud bolt M8x75 2 M8 35
stud bolt M8x66 1 M8 35
Hex.head screw DA M8x25 2 M8 25
Flathead Allen screw M4x8 UNI 5933 1 M4 5
TCEI screw M4x10 2 M4 5
Hex.head screw DA M8x25 1 M8 25
TCEI screw DA M6x30 2 M6 8-12
TCEI screw DA M8x55 cl. 8.8 UNI 5931 dacromet 1 M8 23
TCEI screw M6x16 2 M6 8-12
TCEI screw DA M6x30 1 M6 8-12
TCEI screw DA M6x40 2 M6 8-12
TCEI screw DA M6x60 1 M6 8-12
fitting M24x1.5 2 M24 40
TCEI screw DA M6x55 1 M6 8-12
TCEI screw DA M6x20 2 M6 8-12
copper line nipples M18x1.5 1 M18 20
plug with rod 2 / / /
magnetic plug M10x1.5 1 M10 20
SCREW / NUT
(Nm)
TORQUE
TIGHTENING
Note
2-5
TECHNICAL INFORMATION
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Engine V1100
DESCRIPTION
QUANTITY
LUBRICATION UNIT
TCEI screw DA M8x30
drilled screw M8x1.25
plug M18x1.5
plug M32x1.5
CRANKSHAFT UNIT
connecting rod screw 2 60÷62
nut EBFM ZB MF25x1.5 1 M25 120
FRAME UNIT ON ENGINE
TCEI screw DA M6x40
reduction
IGNITION UNIT
TCEI screw DA M8x45
TCEI screw DA M10x60
nut M10x1.5 flanged
TBEI screw DA M8x50
nut EBFM DA MF16x1.5
spark plug NGK BPR 6ES
spark plug PMR8b
TCEI screw M6x16
FUEL FEED CONTROL UNIT
TCEI screw M5x12
stainl.st.flanged TBEI screw M5x16
TCEI screw DA M6x25
GEAR SHIFT UNIT
Screws securing clutch housing to gearbox
Screws securing bearing to clutch housing
Clutch housing stop screws
Ring nut on clutch shaft
Neutral sensor on gearbox
Magnetic plug
Oil filler cap
Union for breather hose
4 M8 25
1 M8 15-18
1 M18 40
1 M32 40
2 M6 8-12
4 20
1 M8 22
1 M10 see nut
1 M10 30
1 M8 / / /
1 M16 80
2 20-30
2 13-15
4 M6 8-12
2 M5 6-7
2 M5 6-7
6 M6 8-12
14 M6 13
3 M6 10
1 M8 24
1 M22x1 100
1 M8x1 10
1 M10 24
1 M18x1.5 28
1 M10 8
SCREW / NUT
(Nm)
TORQUE
TIGHTENING
Note
2 - 6
Engine V1100
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TECHNICAL INFORMATION
2.1.4. SPECIAL TOOLS
Suitable special tools are necessary for correctly removing, refitting and adjusting.
Unsuitable tools and/or improvised procedures could cause damages that might be avoided if the special tools are used.
Following are the special tools especially designed for this vehicle.
If necessary, request the general special tools.
2-7
TECHNICAL INFORMATION
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Pos. Description Part no.
1 Belt tensioning tool 05.94.86.30
2 Front cover installation cone 05.91.17.30
3 Gearbox opening tool 05.91.25.30
4 Tool for removing the internal spark plug 05.90.19.30
5 Piston ring compression tool 05.92.80.30
6 Timing cover seal drift 05.92.72.30
7 Wrench for removing the cover on sump and filter 01.92.91.00
8 Support for gearbox 14.92.96.00
9 Degree wheel for checking timing 19.92.96.00
10 Index for checking timing 17.94.75.60
11 Tool for removing flange on flywheel side 12.91.36.00
12 Tool for locking the flywheel and the starter gear 12.91.18.01
13 Tool for removing and installing the valves 10.90.72.00
14 Tool for locking the clutch body 30.91.28.10
15 Clutch installing tool 30.90.65.10
16 Tool for installing the seal on flywheel-side flange 14.92.71.00
17 Tool for assembling flywheel-side flange with seal onto crankshaft 12.91.20.00
18 Tool for installing the seal on flywheel-side flange 19.92.71.00
19 Tool for retaining camshaft gear 14.92.73.00
20 Hub for degree wheel 65.92.84.00
21 Tool for removing the clutch hub 05.91.26.30
Engine V1100
2 - 8
Engine V1100
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ENGINE
ENGINE 3
3-1
ENGINE
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Engine V1100
SUMMARY
3.1. REMOVING THE ACCESSORIES ................................................................................................................... 3
3.1.1. REMOVING THE STARTER MOTOR ....................................................................................................... 3
3.1.2. REMOVING THE BLOW-BY SYSTEM...................................................................................................... 4
3.2. GENERATOR ................................................................................................................................................... 6
3.2.1. REMOVING THE GENERATOR ............................................................................................................... 6
3.2.2. INSTALLATION ....................................................................................................................................... 10
3.3. TIMING SYSTEM............................................................................................................................................ 14
3.3.1. REMOVAL AND INSTALLATION ............................................................................................................ 14
3.3.2. TECHNICAL DATA.................................................................................................................................. 18
3.3.3. TIMING .................................................................................................................................................... 19
3.3.4. MEASURING THE SENSOR GAP .......................................................................................................... 21
3.4. OIL PUMP....................................................................................................................................................... 23
3.4.1. REMOVING THE OIL PUMP ................................................................................................................... 23
3.5. HEADS ........................................................................................................................................................... 24
3.5.1. REMOVING THE HEAD COVERS .......................................................................................................... 24
3.5.2. REMOVING THE HEADS........................................................................................................................ 25
3.5.3. CHECKING THE COMPONENTS ........................................................................................................... 30
3.5.4. REASSEMBLING THE HEADS ............................................................................................................... 32
3.6. CYLINDERS AND PISTONS .......................................................................................................................... 37
3.6.1. REMOVAL, CHECK AND INSTALLATION.............................................................................................. 37
3.7. FLYWHEEL..................................................................................................................................................... 42
3.7.1. REMOVAL, CHECK AND REASSEMBLY ............................................................................................... 42
3.8. CRANKSHAFT AND CONNECTING RODS................................................................................................... 44
3.8.1. REMOVAL ............................................................................................................................................... 44
3.8.2. CHECK .................................................................................................................................................... 46
3.8.3. REASSEMBLY ........................................................................................................................................ 49
3.9. OIL SUMP....................................................................................................................................................... 50
3.9.1. REMOVAL, CHECK AND REASSEMBLY ............................................................................................... 50
3 - 2
Engine V1100
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3.1. REMOVING THE ACCESSORIES
3.1.1. REMOVING THE STARTER MOTOR
• Loosen and remove the two screws and collect the
washers.
ENGINE
• Slide out the starter motor.
3-3
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