Cod.

32 92 02 15

USA

00/2004-05

V750 IE

workshopmanual

V750 IE

INTRODUCTION

INTRODUCTION

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INTRODUCTION

V750 IE

SUMMARY
0.1. INTRODUCTION .............................................................................................................................................. 3 0.1.1. INTRODUCTION ....................................................................................................................................... 3 0.1.2. REFERENCE MANUALS .......................................................................................................................... 4 0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS ........................................................................................ 5

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V750 IE 0.1.
0.1.1. -

INTRODUCTION INTRODUCTION
INTRODUCTION

This manual provides the information required for normal servicing. This publication is intended for use by Moto Guzzi dealerships and their qualified mechanics; many concepts have been omitted inasmuch as their inclusion would be superfluous for such an audience. 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. To ensure maximum customer satisfaction with the vehicle, Moto Guzzi spa continuously improves its products and their documentation. The main technical modifications and changes in repair procedures are communicated to all Moto Guzzi dealerships and agencies worldwide. Such modifications will be entered in subsequent editions of the manual. In case of doubt regarding specific repairs or checks, contact the Moto Guzzi SERVICE DEPARTMENT; we will be pleased to provide all necessary information and assistance as well as keeping you updated on changes and modifications 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. The mention of third parties products is only made for information purposes, and constitutes no engagement. Moto Guzzi spa is not liable in any way for the performance or use of its products. For more details see (REFERENCE MANUALS) First edition: May 2004 Designed and printed by: DECA s.r.l. via Risorgimento, 23/1 - 48022 Lugo (RA) - Italy Tel. +39 - 0545 35235 Fax +39 - 0545 32844 E-mail: deca@decaweb.it www.decaweb.it On behalf of: Moto Guzzi s.p.a. via E.V. Parodi, 57- 23826 Mandello del Lario (Lecco) - Italy Tel. +39 (0)341 - 709111 Fax +39 (0)341 - 709220 www.motoguzzi.it www.servicemotoguzzi.com

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INTRODUCTION
0.1.2. REFERENCE MANUALS

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PARTS CATALOGUES guzzi part# (description) GU07500 OWNERS MANUALS guzzi part# (description) 32.90.00.60 32.90.00.61 32.90.00.62 CYCLE PARTS TECHNICAL MANUAL guzzi part# (description) 32.92.01.60 32.92.01.61 32.92.01.62 32.92.01.63 32.92.01.64 32.92.01.65 ENGINE TECHNICAL MANUAL guzzi part# (description) 32.92.02.10 32.92.02.11 32.92.02.12 32.92.02.13 32.92.02.14 32.92.02.15

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0.1.3. # < > ~ C F AC A Ah API HV AV/DC bar DC. cc CO CPU DIN DOHC ECU rpm HC ISC ISO Kg Kgm km kph k kPa KS kW ABBREVIATIONS/SYMBOLS/CONVENTIONS = number = less than = greater than = less than or equal to = more than or equal to = approximately = infinity = degrees Celsius (centigrade) = degrees Fahrenheit = plus or minus = alternating current = Ampere = Ampere per hour = American Petroleum Institute = high voltage = Anti-Vibration Double Countershaft = pressure measurement (1 bar =100 kPa) = Direct Current = cubic centimetres = carbon monoxide = Central Processing Unit = German industrial standards (Deutsche Industrie Norm) = Double Overhead Camshaft = Electronic Control Unit = revolutions per minute = unburnt hydrocarbons = Idle Speed Control = International Standardization Organization = kilograms = kilogram metre (1 kgm =10 Nm) = kilometres = kilometres per hour = kilo Ohm = kiloPascal (1 kPa =0.01 bar) = clutch side (from the German "Kupplungseite") = kiloWatt = litres = racetrack lap = Light Emitting Diode = left side = metres per second = maximum = millibar (1 mbar =0.1 kPa) = miles = minimum = miles per hour = flywheel side (from the German "Magnetoseite") = megaOhm = Not Available = Motor Octane Number = Research Octane Number = Newton metre (1 Nm =0.1 kgm) = ohm = pick-up = Bottom Dead Centre = Top Dead Centre = Pneumatic Power Clutch = right side = Society of Automotive Engineers = diagnostic check = crown-head Allen screw

INTRODUCTION

l
LAP LED LEFT SIDE m/s max mbar mi MIN MPH MS M N.A. N.O.M.M. N.O.R.M. Nm PICK-UP BDC TDC PPC RIGHT SIDE SAE TEST T.B.E.I.

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INTRODUCTION
T.C.E.I. T.E. TP TSI UPSIDEDOWN V W = cheese-head Allen screw = hexagonal head = flat head screw = Twin Spark Ignition = inverted fork = Volt = Watt = Diameter

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V750 IE

GENERAL INFORMATION

GENERAL INFORMATION

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GENERAL INFORMATION

V750 IE

TABLE OF CONTENTS
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 WARNINGS ................................................................................................................................... 5 1.2.1. GENERAL SAFETY RULES .................................................................................................................. 5 1.3. HAZARDOUS SUBSTANCES ......................................................................................................................... 8 1.3.1. WARNINGS ........................................................................................................................................... 8 1.4. RUNNING-IN ................................................................................................................................................. 11 1.4.1. RUNNING-IN........................................................................................................................................ 11 1.5. LOCATION OF SERIAL NUMBERS.............................................................................................................. 12 1.5.1. LOCATION OF SERIAL NUMBERS .................................................................................................... 12

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V750 IE 1.1.
1.1.1.

GENERAL INFORMATION

STRUCTURE OF THE MANUAL

CONVENTIONS USED IN THE MANUAL This manual is divided in sections and subsections, each covering a set of the most significant components. For quick reference, see the summary of sections. Unless expressly specified otherwise, assemblies are reassembled by reversing the disassembly procedure. The terms "left" and "right" are referred to the motorcycle when viewed from the riding position. Motorcycle operation and basic maintenance are covered in the USE AND MAINTENANCE manual.

In this manual any variants are identified with these symbols: optional catalytic version all versions national certification European certification (EURO 1 limits)

MP SF

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 Republic of South Africa New Zealand Canada

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GENERAL INFORMATION
1.1.2. SAFETY WARNINGS

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The following precautionary warnings are used throughout this manual in order to convey the following messages: Safety warning. This symbol appears, whether in the manual or on the vehicle itself, to indicate a personal injury hazard. Non-compliance with the indications given in the messages preceded by this symbol may result in grave 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. IMPORTANT: The word "IMPORTANT" in this manual precedes important information or instructions.

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V750 IE 1.2.
1.2.1.

GENERAL INFORMATION

GENERAL WARNINGS
GENERAL SAFETY RULES

CARBON MONOXIDE When an operation must be performed with the engine running, position the motorcycle outdoors or in a well-ventilated area. Never run the engine in an enclosed place. Use an exhaust emission extraction plant when working indoors. DANGER Exhaust emissions contain carbon monoxide, a poisonous gas that may cause loss of consciousness or even death. FUEL DANGER The fuel used for internal combustion engines is extremely inflammable and in particular conditions it can become explosive. It is important to carry out the refueling and the maintenance operations in a well-ventilated area, with the engine off. Do not smoke when refueling or in the proximity of sources of fuel vapors. Avoid contact with bare flames, sources of sparks or any other source which may ignite the fuel or lead to explosion. DO NOT DISPOSE OF FUEL IN THE ENVIRONMENT. KEEP AWAY FROM CHILDREN. HOT COMPONENT PARTS The engine and exhaust component parts become hot when the engine is running and will stay hot for some time after the engine has been stopped. Wear insulating gloves before handling these components or allow for the engine and exhaust system to cool down before proceeding. EXHAUSTED GEARBOX AND FORK OIL DANGER Wear latex gloves during servicing. Prolonged or repeated contact with gearbox oil may cause severe skin damage. Wash your hands thoroughly after handling gearbox oil. Dispose of gearbox oil through the nearest waste oil reclamation firm or through the supplier. Wear latex gloves during servicing. DO NOT DISPOSE OF OIL IN THE ENVIRONMENT KEEP AWAY FROM CHILDREN. BRAKE FLUID WARNING Brake fluid can damage painted, plastic or rubber surfaces. When servicing the brake system, protect such surfaces with a clean cloth. Always wear safety glasses when servicing the brake system. Brake fluid is extremely dangerous in contact with the eyes. In case of contact with the eyes, rinse abundantly with cool, clean water and immediately seek medical attention. KEEP AWAY FROM CHILDREN.

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GENERAL INFORMATION
HYDROGEN GAS AND BATTERY ELECTROLYTE

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DANGER The battery electrolyte is a toxic, caustic substance containing sulphuric acid and thus able to cause severe burns in case of contact. Wear close-fitting gloves and protective clothing when handling the battery electrolyte. If any battery fluid gets on your skin, rinse the affected area with abundant fresh water. Take special care to protect your eyes - even a small amount of battery fluid can cause blindness. If battery fluid is spilled into your eyes, flush with abundant water for fifteen minutes and contact an eye specialist immediately. If battery fluid is swallowed accidentally, drink abundant water or milk. Immediately seek medical attention and keep drinking milk of magnesia or vegetable oil in the meantime. The battery gives off explosive gases. Keep the battery well away from any sources of ignition, such as flames, sparks, or any heat sources. Make sure the area is well ventilated when servicing or refilling the battery. KEEP AWAY FROM CHILDREN. Battery fluid is corrosive. Avoid spillage. Take special care not to spill battery fluid on plastic parts. Ensure that the electrolyte fluid you are using is the suitable type for your battery. GENERAL PRECAUTIONS AND INFORMATION Follow these instructions closely when repairing, disassembling or reassembling the motorcycle or its components. DANGER Do not use open flames when working on the vehicle. Before proceeding to maintain or inspect the motorcycle, stop the engine and remove the ignition switch key. Ensure that the engine and exhaust system have cooled down. Wherever possible, place the motorcycle on firm and level ground and lift it using suitable equipment. Pay special attention to hot engine parts and the exhaust system: burns hazard. Do not hold mechanical parts or engine components in the mouth, as some of them are made of toxic materials. Unless otherwise specified, re-assembly takes place in the reverse order to disassembly. Where a procedure is cross-referred to relevant sections in the manual, proceed sensibly to avoid disturbing any parts unless strictly necessary. Never use abrasive pastes to polish opaque paintwork. Never use fuel instead of solvent to clean the motorcycle. Do not use alcohol, petrol or solvents to clean the rubber and plastic parts and the saddle: use only water and mild soap. 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 more details see (HAZARDOUS COMPONENTS) 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 a 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 kept together. These parts will have seated themselves against one another in service as a result of normal wear and tear. Certain components are matched-pair parts and should always be used together or replaced as a set. Keep the motorcycle and its components well away from heat sources.

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V750 IE
REASSEMBLING THE COMPONENTS

GENERAL INFORMATION

DANGER Never reuse circlips or snap rings. These parts must always be renewed once they have been disassembled. When fitting a new circlip or snap ring, open the ends just sufficiently to allow fitment to the shaft. Make a rule to check that a newly-fitted circlip or snap ring has located fully into its groove. Never use compressed air to clean bearings. IMPORTANT: All bearings must run freely with no hardness or noise. Replace any bearings that do not meet these requirements. Use ORIGINAL Moto Guzzi SPARE PARTS only. Use the specified lubricants and consumables. Where possible, lubricate a part before assembly. 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 bearings abundantly before assembly. Make 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 operate 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 light coat of lithium grease along the edges of oil seals. Fit oil seals and bearings with the brand or serial number facing outwards (in view).

ELECTRICAL CONNECTORS Disconnect electrical connectors as follows: failure to follow the instructions can seriously damage the connectors and the wiring: Press down on the locking tab, where fitted. WARNING Never separate two connectors by pulling on the wiring. Grasp both connectors and pull them in opposite directions until they become separated. Remove any dirt, rust, moisture, etc. from inside the connector with compressed air. Ensure that the wires are securely crimped to the terminals inside each connector.

IMPORTANT: A connector will only locate properly into the matching connector when it is inserted in the correct mounting position. Reconnect the two connectors and ensure that they are fully engaged (if fitted with a locking tab, it should click audibly into place).

TIGHTENING TORQUES DANGER Do not forget that the tightening torques of all fastenings on wheels, brakes, wheel spindles and other suspension components are essential to ensuring safe operation of the motorcycle and must be set to the indicated values. Regularly check the tightening torques on all fastenings, and always use a torque wrench when fitting them. Failure to observe these instructions can result in parts loosening or coming away, thus jamming a wheel or creating other problems which could affect the handling of the motorcycle, potentially resulting in serious injury or death.

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GENERAL INFORMATION 1.3.

1.3.1. FUEL

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HAZARDOUS SUBSTANCES
WARNINGS

DANGER The fuel used for internal combustion engines is extremely inflammable and in particular conditions it can become explosive. It is important to carry out the refueling and the maintenance operations in a well-ventilated area, with the engine off. Do not smoke when refueling or in the proximity of sources of fuel vapors. Avoid contact with bare flames, sources of sparks or any other source which may ignite the fuel or lead to explosion. 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 tank to the brim. Tighten the filler cap securely after each refueling. Avoid any contact of the fuel with the skin and the inhalation of vapors; do not swallow fuel or pour it from a receptacle into another by means of a tube. DO NOT DISPOSE OF FUEL IN THE ENVIRONMENT. KEEP AWAY FROM CHILDREN. Use only premium-grade unleaded fuel with a minimum octane rating of 95 (N.O.R.M.) and 85 (N.O.M.M.). LUBRICANTS DANGER Correct lubrication is essential to the safety of the motorcycle. Failure to maintain the lubricant level or the use of incorrect, old or dirty lubricant can cause the engine or transmission to seize, resulting in accidents, serious injury or death. Prolonged or repeated contact with engine oil may cause severe skin damage. Wash your hands thoroughly after handling engine oil. Do not dispose of oil in the environment. Dispose of engine oil through the nearest waste oil reclamation firm or through the supplier. WARNING When filling the vehicle with lubricant, make sure not to spill it. Immediately clean up spilled oil, as it can damage the motorcycle's paint. Oil on the tires can make them very slippery and dangerous to use. In case of oil leaks, do not use the vehicle. Identify the cause of the leak and repair it. ENGINE OIL DANGER Prolonged or repeated contact with engine oil may cause severe skin damage. Wash your hands thoroughly after handling engine oil. 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 during servicing. FRONT FORK FLUID DANGER Modifying the suspension settings or the viscosity of the front fork oil will affect its response. Standard oil viscosity: SAE 20 W. Choose the oil viscosity to determine the type of response required (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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V750 IE
BRAKE FLUID

GENERAL INFORMATION

IMPORTANT This motorcycle is fitted with two (front and rear) disk brakes with independent hydraulic circuits. The information provided below applies to both braking systems. DANGER Do not use the vehicle if the brakes are worn or malfunctioning! The brakes are the most important safety component on the vehicle, and using the vehicle with the brakes in less than perfect condition is very likely to result in an accident, with the risk of serious personal injury or death. The brakes are significantly less effective on a wet road surface. DANGER If the road surface is wet with rain, maintain a double braking distance, inasmuch as both the brakes themselves and the grip of the tires are significantly less effective in such conditions. Water on the brakes, whether due to a recent wash or picked up from the wet road surface, puddles or drains, can result in significantly reduced brake effectiveness. Failure to observe these instructions can result in serious accidents, with the risk of serious personal injury or death. The brakes are essential to your safety. Do not use the vehicle if the brakes are not in perfect working order. Always check the brakes before riding the motorcycle. 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 DISPOSE OF THE FLUID IN 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. Sudden resistance or clearance problems on the brake levers may be due to troubles in the hydraulic circuits. Ensure that the brake discs and friction material 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. Avoid accidental ingress of water or dust into the circuit. Wear latex gloves when servicing the hydraulic circuit. DISK BRAKES DANGER The brakes are the vehicles most important safety component. To ensure your personal safety, they must be in perfect working order and should be checked before every ride. Oil or other liquids on the disks will contaminate the brake pads. Dirty pads must be replaced. A dirty or oily disk should be cleaned with a high quality degreaser. If the vehicle is often used on wet road surfaces or on dusty or rough tracks, or in case of use in competition, reduce the service intervals by half. Check the wear of the brake pads. When the pads are worn, the fluid level in the tank lowers to compensate for the wear. The front brake fluid reservoir is on the RH side of the handlebar, next to the front brake lever. The rear brake fluid reservoir is under the RH side fairing. Do not use the vehicle if the brake system is leaking in any position.

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GENERAL INFORMATION
COOLANT

V750 IE

DANGER Coolant is toxic when ingested and is an irritant, contact with eyes or skin may cause irritation. On the event of contact with the skin or the eyes, rinse repeatedly with abundant water and seek medical advice. If swallowed, provoke vomiting, rinse the mouth and throat with abundant water and immediately seek medical attention. DO NOT DISPOSE OF THE FLUID IN THE ENVIRONMENT. KEEP AWAY FROM CHILDREN. DANGER Take care not to spill coolant onto hot engine parts. It may ignite and produce invisible flames. Wear latex gloves when working on the system. Do not ride when coolant is below the minimum level. Coolant mixture is a 50% solution of water and anti-freeze. This is the ideal solution for most operating temperatures and provides good corrosion protection. This solution is also suited to the warm season, as it is less prone to evaporative loss and will reduce the need for topups. In addition, less water evaporation means fewer minerals salts depositing in the radiator, which helps preserve the efficiency of the cooling system. When the outside temperature drops below freezing, check the coolant circuit frequently and add more anti-freeze (up to 60% maximum) to the solution. Use distilled water in the coolant mixture. Tap water will damage the engine. Refer to the chart given below and add water with the quantity of anti-freeze to obtain a solution with the desired freezing point: Freezing point F (C) -4 (-20) -22 (-30) -40 (-40) Coolant % of volume 35 45 55

IMPORTANT The different brands of anti-freeze available on the market have varying specifications. Always read product label to determine the degree of protection afforded. WARNING Use only nitrite-free anti-freeze and corrosion inhibitors with a freezing point of -35C as a minimum. TIRES WARNING An overinflated tire results in a hard, uncomfortable and less secure ride. Overinflation also affects grip, especially on curves and in the wet. An underinflated tire (insufficient pressure) can slip on the wheel rim, resulting in loss of control. Underinflation also affects grip and handling, as well as braking efficiency. Tire replacement and repair, and wheel servicing and balancing are delicate operations. They should be carried out using adequate tools and are best left to experienced mechanics. New tires may be covered by a thin protective cover which has reduced grip. Ride carefully for the first few kilometers (miles). Never use any kind of rubber treatment product on the tires. In particular, take care not to allow the tire to come into contact with liquid fuel, which rapidly deteriorates the tire rubber. A tire which has come into contact with oil or fuel cannot be cleaned and must be replaced. DANGER Certain OEM tires are equipped with wear indicators. There are various types of wear indicators. Contact your Dealership for tire checking information. Check tire wear visually and have the tires replaced when they are worn. If a tire deflates during a ride, do not attempt to continue the trip. Avoid sudden braking or steering maneuvers, and do not decelerate rapidly. Slowly decelerate and move to the edge of the road braking with the engine until you come to a standstill. Failure to observe these instructions can result in serious accidents, with the risk of serious personal injury or death. Never use tube tires on tubeless tire rims, or vice versa.

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V750 IE 1.4.
1.4.1.

GENERAL INFORMATION

RUNNING-IN
RUNNING-IN

Proper engine running-in is essential to preserving engine life and performance over time. Twisty roads and gradients are ideal to break in engine, suspension and brakes effectively. Varying speed frequently is also recommended. This will vary the amount of stress placed on vehicle components continuously, allowing engine parts to cool down when less stressed. While it is important to put a certain amount of stress to engine components during the running-in period, it is equally important to spare the engine at this stage in vehicle's life. WARNING Top acceleration performance is only obtained after covering the first 1243 mi (2000 km). Observe the following instructions: Avoid harsh accelerations and do not flip the throttle open abruptly when the engine is running at low speed, both during and after the running-in period. Apply the brakes gently and avoid hard, prolonged braking for the first 62 mi (100 km). This will allow the brake pad lining to wear in properly rubbing on the brake discs. Never exceed 5000 rpm during the first 932 mi (1500 km) (see chart). WARNING After the first 932 mi (1500 km), perform the checks listed in the post running-in column of the PERIODIC MAINTENANCE CHART. Failure to perform these checks may lead to personal injury to yourself or third persons, or vehicle damage. Between the first 932 mi (1500 km) and 1243 mi (2000 km), a somewhat brisker riding style is acceptable. Vary your speed and use peak acceleration for just a few instants, to allow the different components to become properly seated against one another. However, avoid exceeding 6000 rpm (see chart). After 1243 mi (2000 km), the engine will be ready for a more demanding use. However, never exceed the maximum engine speed allowed (7600 rpm).

Recommended maximum engine speed in rpm Distance covered in mi (km) 0932 (1500) 9321243 (15002000) Over 1243 (2000)

Giri/min (rpm) 5000 6000 7600

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GENERAL INFORMATION 1.5.

1.5.1.

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LOCATION OF SERIAL NUMBERS

LOCATION OF SERIAL NUMBERS

These numbers are necessary for vehicle registration. IMPORTANT: Altering the identification numbers of vehicle or engine is a legal offence punishable by heavy fines and penalties. In addition, altering the frame number (VIN) results in immediate warranty invalidation.

ENGINE NUMBER The engine number is punched on the right hand side of the engine next to the oil level plug.

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PERIODIC MAINTENANCE

PERIODIC MAINTENANCE

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PERIODIC MAINTENANCE

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TABLE OF CONTENETS
2.1. GENERAL TECHNICAL INFORMATION ......................................................................................................... 3 2.1.1. TECHNICAL DATA.................................................................................................................................... 3 2.1.2. LUBRICANT CHART ................................................................................................................................. 4 2.1.3. TIGHTENING TORQUES .......................................................................................................................... 5 2.1.4. SPECIAL TOOLS ...................................................................................................................................... 6

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V750 IE 2.1.
2.1.1.

PERIODIC MAINTENANCE

GENERAL TECHNICAL INFORMATION

TECHNICAL DATA

ENGINE TRANSMISSION ENGINE Type Number of cylinders Cylinder layout Pistons Bore Stroke Total displacement Cooling Air cleaner Compression ratio Maximum horsepower (CE correction) Maximum torque (CE correction) Engine idle rpm Two-cylinder 4-stroke Two 90 V forged, two compression rings, one oil control ring 3.14 in (80 mm) 2.91 in (74 mm) 45.40 cu in (744 cc) Air dry cartridge type 9.6:1 35.5 kW at 6800 rpm 40.34 ftlb (54.7 Nm) at 3600 rpm 1100 100 rpm

TIMING Timing diagram: 2 valves with push-rods and rockers intake valve opens 18 B.T.D.C. intake valve closes 50 A.B.D.C. exhaust valve opens 53 B.B.D.C. exhaust valve closes 15 A.T.D.C. Values valid with clearance between rockers 0.006 in (0.15 mm) intake and valve 0.008 in (0.20 mm) exhaust FUEL SUPPLY Type Choke Fuel STARTING Electric EXHAUST Three-way manifold with catalyzer TRANSMISSION - clutch - primary transmission - gearbox - gear ratios: 1st 2nd 3rd 4th 5th - final transmission - ratio Lubrication SPARK PLUGS Standard Spark plug gap Resistance CAPACITIES Engine oil Transmission oil Gearbox oil Electronic injection (Weber Marelli) 1.42 in (36 mm) Premium grade unleaded petrol, minimum octane rating 95 (N.O.R.M.) and 85 (N.O.M.M.)

dry single disc with cush drive gear-type, ratio: 16/21 = 1:1.3125 5 gears 11/26 = 1:2.3636 14/23 = 1:1.6429 18/23 = 1:1.2778 18/19 = 1:1.0556 20/18 = 1:0.9 cardan shaft type 8/33 = 1:4.825 Pressure system, valve adjustment, lobe pump NGK BR8ES 0.024 0.028 in (0.6 0.7 mm) 5 K

Oil and filter change 1.78 l (0.47 gal) 170 cm3 (10.37 in3) 1000 cm3 (61 in3)

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PERIODIC MAINTENANCE

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2.1.2.

LUBRICANT CHART PRODUCT RECOMMENDED: RACING 4T Alternatively, use quality branded oil with performance equal to or better than CCMC G-4 A.P.I. SG. RECOMMENDED: RECOMMENDED: TRUCK GEAR 85 W 140 ROTRA MP/S 80 W 90

LUBRICANT Engine oil

Transmission oil Gearbox oil Bearings and other lubrication points

RECOMMENDED: BIMOL GREASE 481, AUTOGREASE MP or GREASE SM2. As an alternative to recommended grease, use quality branded rolling bearing grease with operating temperature -30C...+140C, with dropping point 150C...230C, high corrosion protection, good resistance to water and oxidisation.

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V750 IE
2.1.3. TIGHTENING TORQUES

PERIODIC MAINTENANCE

DESIGNATION
CYLINDER HEADS Cylinder head covers fixing screws Spark plugs CRANKCASE AND COVERS Cylinder heads-barrels to crankcase fixing nut (M10) Cylinder heads-barrels to crankcase fixing nut (M8) Crankcases joining nuts (M8) Crankcases joining nuts (M10) Timing cover fixing screws Oil sump fixing screws Valves cover insert fixing screws CONNECTING ROD GROUP Connecting rod screws Flywheel to crankshaft fixing screws Ring gear fixing screws TIMING UNIT Camshaft to crankcase fixing connection Timing gear to camshaft fixing screws Phonic wheel fixing screws ELECTRIC STARTING Starter motor fixing screws FUEL SUPPLY Injector cap fixing screws M5 Intake manifolds to heads fixing screws LUBRICATION Engine oil pressure sensor Oil pump to crankcase fixing screws Filter cartridge sealing cover fixing screw IGNITION Alternator stator fixing screws Alternator rotor nut CLUTCH Clutch shaft fixing nut GEARBOX Primary shaft fixing nuts Cover to gearbox fixing screws Gearbox to clutch housing cover fixing screws Index lever fixing nut 3,69 59 2,95 7,38 7,38

TIGHTENING TORQUES (ftlb)

18,44

29.5030.98 20.6522.13 16.2318.44 29.5030.98 7,38 7,38 3,69

22.1323.60 29,5 7,38

22,13 18,44 18,44

18,44

5.907.38 7,38 18,44

73.76

47.94 7,38 7,38 4,42

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PERIODIC MAINTENANCE

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2.1.4.

SPECIAL TOOLS

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Key: Location 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

PERIODIC MAINTENANCE

Tool designation and application Bush for fitting oil seal on secondary shaft Tool for fitting oil seal on timing cover (crankshaft) Valves disassembly / assembly tool Punch for bevel gear pair pinion oil seal Bevel gear pair alignment preassembly tool Punch for clutch shaft bearing on case Punch for transmission case oil seal Punch for clutch shaft oil seal Punch for assembling oil seal on gearbox cover for secondary shaft Clutch disk assembly and centring tool Flywheel holder tool Spacer for installation of ring on secondary shaft Puller for internal ring on hollow shaft Puller for transmission case bearing external ring Punch for bearing on bevel gear pair pinion Intermediate gear holding tool for removal of gearbox Punch for primary shaft bearing on gearbox Punch for taper roller bearing outer race on bevel gear pair pinion holder body Punch for transmission case bearing outer race Puller for swing arm holder bearing on gearbox cover Reducer bush for valve disassembly tool (this tool is marked with No. 10 90 72 00) Punch for driving bearing inner race onto hollow shaft Tool for assembling oil seal on crankshaft - flywheel side Punch for driving oil seal onto flange and crankshaft flywheel side Clutch shaft holding tool Clutch shaft nut holding wrench Gearbox support Graduated disk Punch for mounting cap on valve guide Tool for assembling oil seal to timing cover (camshaft) Secondary shaft bearing outer race inserter tool

Part number 19 92 73 00 19 92 72 20 10 90 72 00 19 92 61 00 19 92 88 00 19 92 94 00 19 92 60 00 19 90 59 00 19 92 72 00 19 90 65 00 19 91 18 00 19 92 72 02 19 90 70 00 19 92 75 00 19 92 62 00 19 92 77 00 19 92 63 00 19 92 64 00 19 92 65 00 19 92 76 00 19 92 78 00 19 92 79 00 12 91 20 00 19 92 71 00 19 90 71 60 19 90 54 60 19 90 25 00 19 92 96 00 19 92 60 20 19 92 73 20 19 92 64 60

2-7

V750 IE

GEARBOX

GEARBOX

3-1

GEARBOX

V750 IE

TABLE OF CONTENTS
3.1. GEARBOX ........................................................................................................................................................ 3 3.1.1. DISASSEMBLY ......................................................................................................................................... 3 3.1.2. REASSEMBLY .......................................................................................................................................... 7 3.1.3. TIGHTENING TORQUES ........................................................................................................................ 11 3.2. CLUTCH HOUSING........................................................................................................................................ 12 3.2.1. DISASSEMBLY ....................................................................................................................................... 12 3.2.2. REASSEMBLY ........................................................................................................................................ 15 3.2.3. TIGHTENING TORQUES ........................................................................................................................ 19 3.3. TRANSMISSION............................................................................................................................................. 20 3.3.1. TRANSMISSION GEARS ........................................................................................................................ 20

3-2

V750 IE 3.1.
3.1.1.

GEARBOX

GEARBOX
DISASSEMBLY Fit the clutch shaft to the gearbox in such a way that the gear itself meshes with the primary shaft gear.

Fit the provided holding tool to the grooves in the clutch shaft.

Undo the nut retaining the intermediate gear and extract the thrust washer.

3-3

GEARBOX

V750 IE

Remove the gear and the clutch shaft.

Unscrew the breather cap together with its lug.

3-4

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Undo and remove the neutral gear indicator.

GEARBOX

Undo the bolts retaining the gearbox cover and remove it by tapping lightly with a mallet.

Slacken off the locknut and undo the preselector adjuster eccentric screw.

3-5

GEARBOX

V750 IE

Extract the preselector and remove its seal ring.

After having removed the retainer plate fixing screws, remove the entire gearing, shaft and fork assembly.

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3.1.2. REASSEMBLY

GEARBOX

REASSEMBLING THE PRESELECTOR After having refitted the entire gearing assembly including shafts to the gearbox cover, fit the spring and its two extensions over the preselector pawl, making sure that the spacing between the spring extensions is the same on the pawl as between their free extremities.

Refit the eccentric adjuster screw and locknut to the cover, taking care that the eccentric section of the screw is oriented towards the preselector nut.

3-7

GEARBOX
Refit the preselector spacer.

V750 IE

Fit the preselector to the cover, making sure that the two spring extensions fit into the concavity in the adjuster screw. Turn the screw by 90 and tighten down the lock nut.

Refit the gasket, and tighten the gearbox cover screws to their specified torque.

3-8

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GEARBOX

Fit the gear and washer to the primary shaft and tighten the fixing nut to the specified torque and snug it in with a punch.

3-9

GEARBOX

V750 IE

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3.1.3. TIGHTENING TORQUES

GEARBOX

GEARBOX Primary shaft fixing nuts Cover to gearbox fixing screws Gearbox to clutch housing cover fixing screws Index lever fixing nut 47.94 ftlb 7.38 ftlb 7.38 ftlb 4.42 ftlb

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GEARBOX 3.2.
3.2.1.

V750 IE

CLUTCH HOUSING
DISASSEMBLY Once the gearbox/clutch housing are mounted to the holder, itself locked in a vice, fit the holding tool and slacken off the nut by rotating the shaft with the provided tool.

Unscrew the Allen screws securing the clutch housing to the gearbox.

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Disconnect and remove the housing complete with clutch shaft, using light taps with a mallet around the rim of the housing itself.

GEARBOX

Remove the gasket.

Unscrew the three screws with washers and remove the bearing plate.

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GEARBOX

V750 IE

Undo the clutch shaft fixing nut.

Extract the clutch shaft and remove the seal ring.

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3.2.2. REASSEMBLY Refit the clutch shaft by lightly tapping with a plastic mallet, refit the circlip and seal ring.

GEARBOX

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GEARBOX
Fit the retaining plate and screw in the screws with washers (use thread sealant).

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Fit the clutch housing gasket and locate the housing itself.

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Screw in the Allen bolts and external screws and tighten to their specified torque.

GEARBOX

Screw in the clutch shaft nut with the provided tool and snug it in with a punch.

Fit the breather cap.

3 - 17

GEARBOX
Screw in the neutral gear switch.

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Fit the clutch control rod to the shaft with its larger end oriented towards the control lever.

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3.2.3. TIGHTENING TORQUES

GEARBOX

CLUTCH Clutch shaft fixing nut 73.76 ftlb

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GEARBOX 3.3.
3.3.1.

V750 IE

TRANSMISSION
TRANSMISSION GEARS

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.

Primary shaft Gear Clearance washer Circlip Gear Gear Roller cage Gear Intermediate gear Bearing Thrust washer Safety nut Bearing Secondary shaft Spacer Bearing Spacer Seal ring Circlip Gear Gear Gear Gear Gear

25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48.

Thrust washer Bearing Shim Drip collector Circlip Spring washer Spring washer Gear selector drum Pawl Circlip Fork Fork Roller Pin Preselector assembly Spacer Selector return spring Lever Washer Spring Plate Screw Washer Nut

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ENGINE

ENGINE

4-1

ENGINE

V750 IE

TABLE OF CONTENTS
4.1. GEARBOX AND STARTER MOTOR REMOVAL ............................................................................................. 4 4.1.1. REMOVAL THE GEARBOX FROM THE ENGINE .................................................................................... 4 4.1.2. REMOVING THE STARTER MOTOR ....................................................................................................... 5 4.1.3. REMOVING THE OIL INTAKE PIPE FROM THE CRANKCASE .............................................................. 6 4.1.4. TIGHTENING TORQUES .......................................................................................................................... 7 4.2. CYLINDER HEAD COVERS............................................................................................................................. 8 4.2.1. CYLINDER HEAD COVERS REMOVAL ................................................................................................... 8 4.2.2. INSPECTION............................................................................................................................................. 9 4.2.3. REASSEMBLY ........................................................................................................................................ 10 4.2.4. TIGHTENING TORQUES ........................................................................................................................ 11 4.3. TIMING ........................................................................................................................................................... 12 4.3.1. REMOVING THE FRONT ENGINE COVER ........................................................................................... 12 4.3.2. DISASSEMBLING THE ALTERNATOR .................................................................................................. 13 4.3.3. REV AND STROKE SENSOR REMOVAL............................................................................................... 15 4.3.4. REMOVING THE TIMING UNIT COVER................................................................................................. 16 4.3.5. TIMING UNIT INSPECTION .................................................................................................................... 18 4.3.6. REASSEMBLING THE TIMING UNIT ..................................................................................................... 21 4.3.7. TIMING CHECK....................................................................................................................................... 24 4.3.8. ASSEMBLING THE PHONIC WHEEL..................................................................................................... 26 4.3.9. CHECKING THE AIR GAP AND REASSEMBLING THE SENSOR ........................................................ 27 4.3.10. REASSEMBLING THE ALTERNATOR................................................................................................ 29 4.3.11. TIMING DATA ...................................................................................................................................... 31 4.3.12. TIGHTENING TORQUES .................................................................................................................... 32 4.4. ENGINE PRESSURE PLATE FLYWHEEL ..................................................................................................... 33 4.4.1. DISASSEMBLING THE FLYWHEEL ....................................................................................................... 33 4.4.2. INSPECTION........................................................................................................................................... 35 4.4.3. ASSEMBLING THE CLUTCH PLATE AND DISK.................................................................................... 36 4.4.4. TIGHTENING TORQUES ........................................................................................................................ 38 4.5. ENGINE PRESSURE PLATE FLYWHEEL ..................................................................................................... 39 4.5.1. DISASSEMBLING THE FLYWHEEL ....................................................................................................... 39 4.5.2. INSPECTION........................................................................................................................................... 41 4.5.3. REASSEMBLING THE PRESSURE PLATE FLYWHEEL ....................................................................... 42 4.5.4. TIGHTENING TORQUES ........................................................................................................................ 44 4.6. CYLINDER HEADS ........................................................................................................................................ 45 4.6.1. DISASSEMBLING THE CYLINDER HEADS ........................................................................................... 45 4.6.2. DISASSEMBLING THE VALVES FROM THE CYLINDER HEADS ........................................................ 47 4.6.3. DISASSEMBLING THE VALVE GUIDE FROM THE CYLINDER HEAD ................................................. 49 4.6.4. REASSEMBLING AND CHECKING THE VALVE SEATS....................................................................... 50 4.6.5. RE-CUTTING THE VALVE SEATS ......................................................................................................... 52 4.6.6. SPRING PACK INSPECTION ................................................................................................................. 55 4.6.7. REASSEMBLING THE CYLINDER HEADS ............................................................................................ 57 4.6.8. TIGHTENING TORQUES ........................................................................................................................ 59 4.7. CYLINDERS ................................................................................................................................................... 60 4.7.1. DISASSEMBLING THE CYLINDERS ...................................................................................................... 60 4.7.2. INSPECTION........................................................................................................................................... 61 4.7.3. ASSEMBLING THE CYLINDERS............................................................................................................ 62 4.7.4. TIGHTENING TORQUES ........................................................................................................................ 64 4.8. PISTONS ........................................................................................................................................................ 65 4.8.1. DISASSEMBLING THE PISTONS........................................................................................................... 65 4.8.2. INSPECTION........................................................................................................................................... 66 4.8.3. REASSEMBLING THE PISTONS............................................................................................................ 68 4.9. PISTON RINGS AND OIL CONTROL RING................................................................................................... 70 4.9.1. DISASSEMBLY ....................................................................................................................................... 70 4.9.2. PISTON RINGS INSPECTION ................................................................................................................ 71 4.9.3. REASSEMBLING THE PISTON RINGS AND OIL CONTROL RING ...................................................... 72 4.10. CRANKCASE.................................................................................................................................................. 73 4.10.1. DISASSEMBLING THE CRANKCASE................................................................................................. 73 4.10.2. INSPECTION ....................................................................................................................................... 76 4.10.3. REASSEMBLING THE CRANKCASE.................................................................................................. 77 4.10.4. TIGHTENING TORQUES .................................................................................................................... 81 4.11. CONNECTING RODS .................................................................................................................................... 82 4.11.1. DISASSEMBLING THE CONNECTING RODS ................................................................................... 82 4.11.2. CONNECTING ROD CLEARANCE ..................................................................................................... 83 4.11.3. REASSEMBLING THE CONNECTING RODS .................................................................................... 84 4.11.4. TIGHTENING TORQUES .................................................................................................................... 85 4.12. CRANKSHAFT................................................................................................................................................ 86 4.12.1. DISASSEMBLING THE CRANKSHAFT............................................................................................... 86 4.12.2. CRANKSHAFT INSPECTION .............................................................................................................. 88 4.12.3. TIGHTENING TORQUES .................................................................................................................... 89

4-2

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ENGINE

4.13. OIL SUMP .......................................................................................................................................................90 4.13.1. DISASSEMBLING THE OIL SUMP ......................................................................................................90 4.13.2. OIL SUMP INSPECTION ......................................................................................................................93 4.13.3. REASSEMBLY......................................................................................................................................94 4.13.4. DISASSEMBLING THE OIL PUMP ......................................................................................................96 4.13.5. OIL PUMP INSPECTION ......................................................................................................................98 4.13.6. REASSEMBLING THE OIL PUMP .....................................................................................................100 4.13.7. DISASSEMBLING THE OIL PRESSURE CONTROL VALVE ............................................................101 4.13.8. REASSEMBLING THE OIL PRESSURE CONTROL VALVE .............................................................102 4.13.9. REASSEMBLING THE OIL TRANSMITTER ......................................................................................103 4.13.10. TIGHTENING TORQUES ...................................................................................................................104

4-3

ENGINE 4.1.
4.1.1.

V750 IE

GEARBOX AND STARTER MOTOR REMOVAL

REMOVAL THE GEARBOX FROM THE ENGINE Undo the screws securing the gearbox to the engine

Remove the gearbox

4-4

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4.1.2. REMOVING THE STARTER MOTOR Undo the starter motor fixing screws

ENGINE

Remove the starter motor

4-5

ENGINE
4.1.3. REMOVING THE OIL INTAKE PIPE FROM THE CRANKCASE Remove the oil vapor intake pipe from the crankcase

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4-6

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4.1.4. TIGHTENING TORQUES

ENGINE

ELECTRIC STARTING Starter motor fixing screws 18.44 ftlb

4-7

ENGINE 4.2.
4.2.1.

V750 IE

CYLINDER HEAD COVERS

CYLINDER HEAD COVERS REMOVAL Undo the screws retaining them and remove the covers and gaskets from the cylinder heads

4-8

V750 IE
4.2.2. INSPECTION

ENGINE

Check that the head cover contact surfaces are not damaged and that there are no blowholes

4-9

ENGINE
4.2.3. REASSEMBLY

V750 IE

Replace the cover gaskets and refit the covers to the cylinder heads

Screw in the screws in a crosswise pattern and tighten to the specified torque with a torque wrench

4 - 10

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4.2.4. TIGHTENING TORQUES

ENGINE

CYLINDER HEADS Cylinder head covers fixing screws Spark plugs 7.38 ftlb 18.44 ftlb

4 - 11

ENGINE 4.3.
4.3.1.

V750 IE

TIMING
REMOVING THE FRONT ENGINE COVER Undo the fixing screws and remove the alternator unit covers

4 - 12

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4.3.2. DISASSEMBLING THE ALTERNATOR Unscrew the screws securing the stator to the timing cover and extract it.

ENGINE

Unscrew the rotor to crankshaft fixing nut, withdraw the rotor and remove the key

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4 - 14

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4.3.3. REV AND STROKE SENSOR REMOVAL Remove the two securing screws and slip stroke sensor out.

ENGINE

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ENGINE
4.3.4. REMOVING THE TIMING UNIT COVER Unscrew the fixing screws and remove the timing unit cover and gasket

V750 IE

Remove the chain tensioner

Unscrew the screw retaining the phonic wheel and remove it.

4 - 16

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ENGINE

Remove the two screws and timing gear from the shaft, together with the chain and oil pump gear.

4 - 17

ENGINE
4.3.5. TIMING UNIT INSPECTION

V750 IE

DISASSEMBLING THE ROCKERS Remove the circlips and extract the two rockers and oil delivery connector.

4 - 18

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Check that the pin itself is not excessively worn on the rocker contact surface. Check the valve and rod rocker contact surfaces.

ENGINE

FITTING THE ROCKERS Check that the lengthwise slot is oriented towards the oil delivery line. IMPORTANT Pay special attention to the correct orientation of the washers at the time of reassembly.

Fit the oil delivery connector and rockers to the shaft and secure them with the circlips

4 - 19

ENGINE

V750 IE

Check that the rocker control rods are straight, and that the end contact surfaces show no signs of seizure, otherwise replace them. To check that the pressed ends on the rods are free of clearance, allow the rods to fall onto a flat surface from a small height. If the rods emit a high, sharp sound on impact, the ends are without play.

4 - 20

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4.3.6. REASSEMBLING THE TIMING UNIT Move the left cylinder piston to the top dead centre (PMS) position and check that the crankshaft gear reference mark is at the top on a perpendicular axis .

ENGINE

Position the timing shaft with the gear reference pin downwards.

Fit the (pin) key securing the oil pump shaft.

Fit the two gears with the timing belt and check the position of the reference marks. Tighten the screws with a torque wrench to the specified torque.

4 - 21

ENGINE

V750 IE

Screw the oil pump nut while holding the oil pump shaft itself immobile.

4 - 22

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Fit the chain tensioner and tighten to the specified torque with a torque wrench.

ENGINE

4 - 23

ENGINE
4.3.7. TIMING CHECK Fit the goniometer and dial gauge, then move the cylinder to the top dead centre position in compression and read the exact position off the dial gauge.

V750 IE

Reset the goniometer at the top dead centre (PMS) position on the dial.

Adjust the prescribed.

valves

to

the

theoretical

clearance

4 - 24

V750 IE
Turn clockwise until the rod and rockers come into contact and check the intake valve opening advance relative to the top dead centre.

ENGINE

Continue turning until the rod is again free and read the value of the closing delay relative to the bottom dead centre.

Repeat for the other valves. Adjust the clearance of the valves to the specified value.

4 - 25

ENGINE
4.3.8. ASSEMBLING THE PHONIC WHEEL The phonic wheel is located by a pin on the timing shaft. Fit the phonic wheel correctly to the timing shaft with the pin located in the slot, and tighten to the specified torque with a torque wrench.

V750 IE

Fit the gasket and timing unit cover, and tighten to the specified torque with a torque wrench.

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4.3.9. CHECKING THE AIR GAP AND REASSEMBLING THE SENSOR Fit a plain washer to the sensor and measure its thickness.

ENGINE

Place the sensor on the timing unit cover and bring it into contact with the phonic wheel.

Use a thickness gauge to measure the gap between the fixing plate and cover. Subtract the thickness of the plain washer to determine the gap between the sensor and phonic wheel.

4 - 27

ENGINE
Remove the washer and fit the sensor after having smeared the fixing plate surface with sealant and tighten the screws to the specified torque.

V750 IE

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4.3.10. REASSEMBLING THE ALTERNATOR

ENGINE

Fit the mounting washer, key and rotor, and close the nut with a torque wrench tightening to the specified torque.

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ENGINE
Fit the stator and its cover and screw in the three retaining screws.

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Fit the stator cover.

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4.3.11. TIMING DATA

ENGINE

Intake: opens 18 before T.D.C.; closes 50 after B.D.C. Exhaust: opens 53 before B.D.C.; closes 15 after T.D.C.

Valve clearance for timing check 0.039 in. Valve clearance for operation: intake 0.006 in (mm 0.15); exhaust 0.008 in (mm 0.20).

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ENGINE
4.3.12. TIGHTENING TORQUES

V750 IE

TIMING UNIT Camshaft to crankcase fixing connection Timing gear to camshaft fixing screws Phonic wheel fixing screws 22.13 ftlb 18.44 ftlb 18.44 ftlb

4 - 32

V750 IE 4.4.
4.4.1.

ENGINE

ENGINE PRESSURE PLATE FLYWHEEL

DISASSEMBLING THE FLYWHEEL Remove the circlip and clutch engage/disengage retainer.

Unscrew the screws securing the pressure plate flywheel to the crankshaft and remove it.

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ENGINE

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4.4.2. INSPECTION Check that the clutch disk is not scored or heavily worn.

ENGINE

Check the cush drive springs, and make sure the clutch disk is not worn to less than the specified thickness, otherwise replace it.

Check the wear of the gear teeth and clutch disk contact surface.

4 - 35

ENGINE
4.4.3. ASSEMBLING THE CLUTCH PLATE AND DISK Fit the specified flywheel locking tool.

V750 IE

Fit the retainer and seal ring.

Fit the clutch disk centring tool to the plate and seat the disk.

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Fit the assembly onto the pressure plate flywheel and tighten the screws to the specified torque.

ENGINE

4 - 37

ENGINE
4.4.4. TIGHTENING TORQUES

V750 IE

CLUTCH Clutch shaft fixing nut 73.76 ftlb

4 - 38

V750 IE 4.5.
4.5.1.

ENGINE

ENGINE PRESSURE PLATE FLYWHEEL

DISASSEMBLING THE FLYWHEEL Remove the circlip and clutch engage/disengage retainer.

Unscrew the screws securing the pressure plate flywheel to the crankshaft and remove it.

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4.5.2. INSPECTION Check that the flywheel is not scored on the disk contact surface. Check that the crankshaft seating is not deformed, otherwise replace the flywheel.

ENGINE

4 - 41

ENGINE
4.5.3. REASSEMBLING THE PRESSURE PLATE FLYWHEEL When reassembling the pressure plate flywheel to the crankshaft, make sure that the yellow mark on the shaft is perfectly aligned with the groove on the flywheel itself.

V750 IE

Screw in the screws and fit the flywheel locking tool.

Tighten down the screws in a crosswise pattern to the specified torque using a torque wrench. We recommend replacing the engine shaft flywheel fixing screws.

Fit the clutch engage/disengage retainer and circlip.

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ENGINE

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ENGINE
4.5.4. TIGHTENING TORQUES

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CONNECTING ROD GROUP Connecting rod screws Flywheel to crankshaft fixing screws Ring gear fixing screws 22.1323.60 ftlb 29.5 ftlb 7.38 ftlb

4 - 44

V750 IE 4.6.
4.6.1.

ENGINE

CYLINDER HEADS
DISASSEMBLING THE CYLINDER HEADS Unscrew the nuts fixing the cylinder heads, cylinders and rocker pins to the crankcase in a crosswise pattern.

Remove the upper spacers, pins complete with rockers, lower spacers and rocker control rods and remove the heads from the stud bolts.

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4.6.2. DISASSEMBLING THE VALVES FROM THE CYLINDER HEADS Fit the specified tool to the upper cup and at the centre of the head of the valve in question.

ENGINE

Tighten down the tool so as to compress the spring and knock the head of the tool with a mallet to remove the two half cones from the upper cup.

Slacken off the tool and remove it from the head.

4 - 47

ENGINE
Extract the upper cup, the spring and the valve itself.

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4.6.3. DISASSEMBLING THE VALVE GUIDE FROM THE CYLINDER HEAD Remove the valve guide gaskets and extract the lower spring cup.

ENGINE

IMPORTANT The valve guides should be replaced when worn to the point that when only the valve is replaced the clearance between the valve stem and its seat in the valve guide can no longer be eliminated.

The valve guides are removed with the aid of a special punch, knocking outwards with a mallet; to facilitate the procedure, heat the head to 50-60 degrees.

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ENGINE
4.6.4. REASSEMBLING AND CHECKING THE VALVE SEATS Drive the valve guides into the head using the special punch and mallet and knocking inwards; to facilitate the operation, heat the head to around 60C (140F).

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Once the valve guides are seated, ream its internal diameter to the value given in the table.

Valves and valve guides assembly data

Intake Exhaust

VALVE GUIDE INTERNAL DIAMETER in (mm) 0.21650.2173 (5.5005.520) 0.21650.2173 (5.5005.520)

VALVE STEM DIAMETER in (mm) 0.21570.2151 (5.4805.465) 0.21570.2151 (5.4805.465)

ASSEMBLY CLEARANCE in (mm) 0.00070.0021 (0.0200.055)

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ENGINE

INTAKE A in (mm) 1.25981.2596 (32.032.25) EXHAUST A in (mm) 1.09131.1011 (27.7227.97) B (theoretical) in (mm) 1.1810 (30) C (theoretical) in (mm) 0.0629 (1.6) D in (mm) 0.0448 (1.14) B (theoretical) in (mm) 1.3385 (34) C (theoretical) in (mm) 0.0559 (1.42) D in (mm) 0.0393 (1)

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ENGINE
4.6.5. RE-CUTTING THE VALVE SEATS

V750 IE

IMPORTANT The valve seats must be re-cut when the valve guides are replaced or in case of excessive clearance. Choose the appropriate pilot tool and mount it to the valve guide.

Select the appropriate mill for the diameter and angle of the valve seat itself. Fit the mill to the pilot and lower it gently to the level of the valve seat.

Fit the T-handle to the mill shank and turn it clockwise with a light pressure to mill out the valve contact surface evenly.

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ENGINE

Repeat the operation with the appropriate tool to mill out the valve seat.

Remove the tools at the end of the operation. Insert the lower spring seats and fit the gaskets to the valve guides using the specified tool.

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ENGINE

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4.6.6. SPRING PACK INSPECTION

ENGINE

With the assembly (cups, springs, valves and half-cones) installed on the heads, the external springs must be compressed by 1.4173 in (36 mm). Note that at their fully open position the valves must have an additional 0.039 in (1 mm) excursion before the internal spring is completely compressed. If necessary add or remove shims until the above dimension is obtained.

Free length

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ENGINE
SPRING CHARACTERISTICS DESCRIPTION External diameter Internal diameter Wire diameter Free length Solid length Test length L1 Test length L2 Measured test load P1 Measured test load P2 Coil direction Spring class to UNI 7900/4 UNIT in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) lb (Kg) lb (Kg) / / VALUE /

V750 IE

0.7007 0.0078 (17.8 0.2) 0.1338 0.0011 (3.4 0.03) 1.7165( 43.6) 1.0826 (27.5) 1.4173 (36) 1.1023(28) 38.8 5% (17.6 5%) 97 3% (44 3%) right-hand CC

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4.6.7. REASSEMBLING THE CYLINDER HEADS Fit the new gasket and seat the cylinder head.

ENGINE

Insert the lower rocker spacers, rocker control rods, rockers and upper spacers with their nuts.

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ENGINE

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Tighten down the nuts in a crosswise pattern to the specified torque.

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4.6.8. TIGHTENING TORQUES

ENGINE

CYLINDER HEADS Cylinder head covers fixing screws Spark plugs 7.38 ftlb 18.44 ftlb

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ENGINE 4.7.
4.7.1.

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CYLINDERS
DISASSEMBLING THE CYLINDERS Remove the cylinders and gaskets from the stud bolts.

Remove the O-ring between the crankcase and cylinder.

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4.7.2. INSPECTION First check for superficial scoring and then check wear of the cylinder bore surfaces using a dial gauge. Measure the inside diameter of the cylinder bore at three different heights, then turn the dial gauge through 90 and repeat the measurements; the dial gauge must be first zero set on a ring gauge.

ENGINE

Key: 1. 1st measurement 2. 2nd measurement 3. 3rd measurement 4. control dimension for selection

Cylinder diameter selection GRADE D in (mm) 3.1496 3.1499 (80.00080.010) GRADE E in (mm) 3.1499 3.1504 (80.01080.020) GRADE F in (mm) 3.1504 3.1508 (80.02080.030)

When fitting new units, cylinder grades "D-E-F" must be paired with pistons selected for the corresponding grade. Assembly clearance between piston and cylinder: 0.0019 0.0027 in (0.050 0.070 mm).

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4.7.3. ASSEMBLING THE CYLINDERS Check that the piston rings are mounted with their slots at 120 degrees out of phase from each other.

V750 IE

Fit the new gasket and the O-ring to the crankcase, and fit a standard piston ring compressor tool to the piston.

Lubricate the cylinder bore and the piston. Knock the piston into the cylinder with the aid of a plastic mallet.

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ENGINE

Once the piston is inserted beyond its rings, remove the compression tool and seat the cylinder.

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ENGINE
4.7.4. TIGHTENING TORQUES

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CRANKCASE AND COVERS Cylinder heads-barrels to crankcase fixing nut (M10) Cylinder heads-barrels to crankcase fixing nut (M8) Crankcases joining nuts (M8) Crankcases joining nuts (M10) Timing cover fixing screws Oil sump fixing screws Valves cover insert fixing screws 29.5030.98 ftlb 20.6522.13ftlb 16.2318.44 ftlb 29.5030.98 ftlb 7.38 ftlb 7.38 ftlb 3.69 ftlb

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V750 IE 4.8.
4.8.1.

ENGINE

PISTONS
DISASSEMBLING THE PISTONS Protect the cylinder seat and remove the two gudgeon pin clips.

Extract the gudgeon pin using the specified screw tool, and remove the piston.

IMPORTANT When overhauling the engine decoke the piston crowns and piston ring grooves.

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4.8.2. INSPECTION First check for superficial scoring and then check wear of the cylinder bore surfaces using a dial gauge. Measure the inside diameter of the cylinder bore at three different heights then turn the dial gauge through 90 and repeat the measurements; the dial gauge must be first zero set on a ring gauge.

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Key: 1. 2. 3. 4. 1st measurement 2nd measurement 3rd measurement control dimension for selection

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Check the piston diameter at the specified height and on an axis perpendicular to the gudgeon pin. Selection values refer to the bare piston (without graphite facing).

ENGINE

Check that the selection mark and assembly arrows are punch marked on the piston.

Piston diameter selection GRADE D in (mm) 3.1472 3.1476 (79.94079.950) GRADE E in (mm) 3.1476 3.1480 (79.95079.960) GRADE F in (mm) 3.1480 3.1484 (79.96079.970)

IMPORTANT Graphite facing thickness when new: 0.00060.0002 in (0.015 0.005 mm). Gudgeon pin to piston bore assembly data GUDGEON PIN EXTERNAL DIAMETER in (mm) 0.7872 0.7874 (19.996 20.000) DIAMETER OF BORES IN PISTON in (mm) 0.8661 0.8663 (22.000 22.006) ASSEMBLY CLEARANCE in (mm) From in 0.0002362 (mm 0.006) clearance to in 0.0000787 (mm 0.002) interference

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ENGINE
4.8.3. REASSEMBLING THE PISTONS To reassemble the piston to the connecting rod small end, heat the piston in an oil bath to around 140 F (60C) to facilitate fitting the gudgeon pin. Fit the gudgeon pin clip and mount the gudgeon pin inserter tool to the piston.

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Position the piston and tool on the connecting rod and screw down to drive in the gudgeon pin.

When the gudgeon pin is installed, remove the tool and fit the second clip to secure the pin, having first protected the cylinder seat.

IMPORTANT The mounting position is shown by an arrow pointing in the direction of travel (forwards).

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ENGINE

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ENGINE 4.9.
4.9.1.

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PISTON RINGS AND OIL CONTROL RING

DISASSEMBLY Remove the piston rings and oil control ring.

IMPORTANT Do not overstretch the piston rings when extracting them from the piston as they may break.

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4.9.2. PISTON RINGS INSPECTION Use a feeler gauge to check that the assembly clearance between ring and ring groove on the piston is as specified.

ENGINE

top piston ring in 0.00118 0.00244 (mm 0.030 0.062); middle piston ring in 0.00118 0.00244 (mm 0.030 0.062); oil control ring in 0.00118 0.00244 (0.030 0.062 mm).

Insert the piston rings one at a time into the cylinder square to the cylinder wall and use a feeler gauge to check the end gap.

top and middle piston rings: in 0.00984 0.01771 (mm 0.25 0.45); oil control ring in 0.00787 0.01771 (mm 0.20 0.45).

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4.9.3. REASSEMBLING THE PISTON RINGS AND OIL CONTROL RING Fit the piston rings paying attention to the position of slots and rings and making sure to space the slots at 120 around the piston.

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V750 IE 4.10. CRANKCASE

4.10.1. DISASSEMBLING THE CRANKCASE Unscrew the four internal crankcase nuts and the six external ones.

ENGINE

Fit a rod into the seat of the tie rod securing the engine to the frame and lightly knock it with a plastic mallet to separate the two halves of the crankcase.

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Remove the upper crankcase half, taking care not to damage the contact surfaces. Remove the crankshaft complete with connecting rods and half-shells.

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Unscrew the oil pressure sensor from the upper crankcase half and remove the timing shaft retainer bushing; then extract the shaft and tappets and mark them.

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ENGINE

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4.10.2. INSPECTION

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Check that the contact surfaces are in good condition and not scored or dented. Remove the liquid seal residue with trichloroethylene.

Check that the stud bolt threads are not dented or stripped, otherwise replace the stud bolts.

Use compressed air to blow out all lubrication ducts in the two crankcase halves.

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4.10.3. REASSEMBLING THE CRANKCASE

ENGINE

Lubricate and fit the tappets.

Fit the timing shaft into its seat in the upper crankcase half; lubricate, fit and secure the timing shaft retainer bushing.

Fit the timing side and flywheel side half shells to the upper crankcase half together with their thrust washers. Lubricate all parts before installing them.

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V750 IE

Lubricate and fit the seal ring to the engine shaft and mount the assembly to the crankcase, taking care to seat the connecting rods correctly.

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ENGINE

Lubricate and mount the half shells to the lower crankcase half, and smear the crankcase half contact surfaces with the specified sealant.

Mount the two crankcase halves and seat them by knocking lightly with a mallet. Tighten the four central stud bolts and external nuts to the specified torque in a crosswise pattern.

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4.10.4. TIGHTENING TORQUES

ENGINE

CRANKCASE AND COVERS Cylinder heads-barrels to crankcase fixing nut (M10) Cylinder heads-barrels to crankcase fixing nut (M8) Crankcases joining nuts (M8) Crankcases joining nuts (M10) Timing cover fixing screws Oil sump fixing screws Valves cover insert fixing screws 29.5030.98 ftlb 20.6522.13ftlb 16.2318.44 ftlb 29.5030.98 ftlb 7.38 ftlb 7.38 ftlb 3.69 ftlb

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ENGINE 4.11. CONNECTING RODS

4.11.1. DISASSEMBLING THE CONNECTING RODS Once the crankshaft assembly together with connecting rods has been removed from the upper crankcase half, undo the screws and separate the rod from its small end taking care to observe the reference marks and assembly orientation.

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Remove the half shells from the connecting rods and their small ends.

IMPORTANT Repeat for the other connecting rod.

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4.11.2. CONNECTING ROD CLEARANCE

ENGINE

Use a micrometer to check the diameter of the crankpin on its orthogonal axes and in the half shell contact patches, and check the size of the timing side and flywheel side bearing seats. Torque the connecting rod screws to their specified torque without the half shells mounted and use a dial gauge to measure the external diameter of the half shell seats; use a round point micrometer to measure the thickness of the two half shells themselves. Check that the bushes driven into the small ends have no seizing marks or deep scoring; otherwise replace them.

Big end diameter 1.71871.7192 in (43.65743.670 mm). Shaft diameter 1.57461.5748 in (39.99540.001 mm). Clearance between crank pin and connecting rod big end bearing at 90 from the mating faces: min. 0.00078 in (0.020 mm), max. 0.00240 in (0.061 mm). Connecting rod bearing thicknesses NORMAL (production) A B in (mm) in (mm) 0.06050.0607 0.06010.0603 (1.5371.543) (1.5271.533) Diameter of bush driven into connecting rod small end and gudgeon pin INSIDE DIAMETER FOR BUSHING DRIVEN INTO CONNECTING ROD SMALL END in (mm) 0.70900.7094 (18.01018.020) DIAMETER OF GUDGEON PIN in (mm) 0.70850.7086 (17.99618.000) SMALL END BUSHING TO GUDGEON PIN ASSEMBLY CLEARANCE in (mm) 0.000390.00094 (0.0100.024)

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4.11.3. REASSEMBLING THE CONNECTING RODS

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Before fitting the parts take care to observe the reference marks and assembly orientation. Reassemble the connecting rods onto the crankshaft seat on the crank pin and tighten the screws to the specified torque.

CHECKING THE CONNECTING ROD SHIMS Check that the assembly clearance between the connecting rod shims and crankshaft is within tolerance: 0.01040.0202 in (0.2650.515 mm).

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4.11.4. TIGHTENING TORQUES

ENGINE

CONNECTING ROD GROUP Connecting rod screws Flywheel to crankshaft fixing screws Ring gear fixing screws 22.1323.60 ftlb 29.5 ftlb 7.38 ftlb

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ENGINE 4.12. CRANKSHAFT

4.12.1. DISASSEMBLING THE CRANKSHAFT Remove the connecting rods from the crankshaft. Undo the oil cap and carefully clean the oil ducts leading to the connecting rods and main journals.

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ENGINE

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4.12.2. CRANKSHAFT INSPECTION

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Smear the oil cap with thread sealant and screw it in snugly. Use compresed air to clean out the lubrication ducts.

IMPORTANT As the crankshaft is nitrided it cannot be ground; therefore, when it displays wear, out of round, or deep scoring, the crankshaft itself must be renewed.

Diameter of timing side crankshaft journal Normal (production) in (mm) 1.57571.6931 (40.02343.007) Diameter of flywheel side main bearing seat Normal (production) in (mm) 1.85551.8559 (47.13047.142) Total thickness for flywheel side main bearing Normal (production) in (mm) 0.08040.0807 (2.0442.050) Clearance between crankshaft and flywheel side main bearing Normal (production) in (mm) 0.000270.00185 (0.0070.047) Diameter of flywheel side crankshaft journal Normal (production) in (mm) 1.57461.5752 (39.99540.011) Thickness of thrust half washer on flywheel side main bearing Normal (production) in (mm) 0.09090.0929 (2.3102.360) Main bearing journal to shell clearance Normal (production) in (mm) 0.013770.01574 (0.350.40) maximum parallelism error of the two crankshaft axes (crankpin and flywheel / timing side main journals) must be no greater than 0.00078 in (0.02 mm), at a distance of 1.5747 in (40 mm).

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4.12.3. TIGHTENING TORQUES

ENGINE

CONNECTING ROD GROUP Connecting rod screws Flywheel to crankshaft fixing screws Ring gear fixing screws 22.1323.60 ftlb 29.5 ftlb 7.38 ftlb

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ENGINE 4.13. OIL SUMP

4.13.1. DISASSEMBLING THE OIL SUMP Unscrew the screw securing the oil filter to the sump.

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Remove the filter cartridge.

Undo the screws securing the sump to the crankcase and remove it together with its gasket.

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ENGINE

Remove the oil level indicator.

Flatten out the locking tab and remove the mesh filter retainer screw and mesh filter itself from the sump.

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4.13.2. OIL SUMP INSPECTION

ENGINE

Check that the mesh filter is clean, otherwise wash it and blow it out with compressed air.

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4.13.3. REASSEMBLY

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Fit the filter, locking tab and fixing screw and tighten down.

Bend the locking tab.

Fit the gasket between the sump and crankcase (always fit a new one). Take care to fit the gasket correctly as incorrect installation can lead to faulty oil delivery.

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Screw in the sump screws in a crosswise pattern and tighten to the specified torque with a torque wrench.

ENGINE

Fit the filter cartridge and tighten its screw to the specified torque.

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4.13.4. DISASSEMBLING THE OIL PUMP

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After having removed the timing unit, remove the oil pump from the crankcase by undoing the Allen screws. Disassemble the pump as follows:

Remove the fixing key. Extract the pump driveshaft and internal rotor. Extract the external rotor.

Extract the bearings and internal seat from the pump body.

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ENGINE

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4.13.5. OIL PUMP INSPECTION

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OIL PUMP BODY Check that the faces and internal seats of the pump body are not scored, damaged or dented. Oil pump data: of seat for external rotor 1.60031.6013 in (40.65040.675 mm); of bore for pump drive shaft 0.47300.4741 in (12.01612.043 mm); of seat for roller bearings 0.86500.8658 in (21.97221.993 mm); thickness of seat for external rotor 0.74920.7507 in (19.03019.070 mm).

EXTERNAL ROTOR Check that the internal and external surfaces and the faces are not scored or damaged, otherwise renew both rotors. External rotor data: external 1.59601.5972 in (40.54040.570 mm); internal 0.95290.9539 in (24.20524.230 mm); thickness 0.74640.7476 in (18.96018.990 mm).

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INTERNAL ROTOR Check that the internal and external surfaces and the faces are not scored or damaged, otherwise renew both rotors. Internal rotor data: external 1.17101.1720 in (29.74529.770 mm); of bore for pump drive shaft 0.47240.4731 in (12.00012.018 mm); thickness 0.74640.7476 in (18.96018.990 mm).

ENGINE

ROLLER BEARINGS Check that the bearing rollers are not damaged, otherwise renew the bearings.

OIL PUMP DRIVE SHAFT Check that the drive shaft is not damaged and that the threads are in good condition, that the keyway is not burred and that the end that operates in the internal rotor is not damaged, otherwise renew the shaft. Shaft data: for pump body bore 0.47170.4724 in (11.98212.000 mm); for roller bearings 0.39330.3936 in (9.99110.000 mm).

ASSEMBLY CLEARANCES between pump body and external rotor 0.003140.00531 in (0.0800.135 mm); between bore on internal rotor and pump drive shaft 0.000620.00240 in (0.0160.061 mm); between bore on pump body and pump drive shaft 0.000620.00240 in (0.0160.061 mm).

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4.13.6. REASSEMBLING THE OIL PUMP

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Reassemble the oil pump and fit it to the crankcase, with reference to the two centring grub screws. Tighten the Allen screws to the specified torque and check that the drive shaft runs freely.

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4.13.7. DISASSEMBLING THE OIL PRESSURE CONTROL VALVE

ENGINE

Unscrew with the provided tool the control valve from its threaded seat in the crankcase .

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4.13.8. REASSEMBLING THE OIL PRESSURE CONTROL VALVE

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Fit the valve and spring and tighten down the screw to the specified torque with a torque wrench (use thread sealant on the screw threads).

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4.13.9. REASSEMBLING THE OIL TRANSMITTER

ENGINE

Fit the oil sensor led transmitter to its connector and tighten to the specified torque.

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4.13.10. TIGHTENING TORQUES

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CRANKCASE AND COVERS Cylinder heads-barrels to crankcase fixing nut (M10) Cylinder heads-barrels to crankcase fixing nut (M8) Crankcases joining nuts (M8) Crankcases joining nuts (M10) Timing cover fixing screws Oil sump fixing screws Valves cover insert fixing screws 29.5030.98 ftlb 20.6522.13ftlb 16.2318.44 ftlb 29.5030.98 ftlb 7.38 ftlb 7.38 ftlb 3.69 ftlb

LUBRICATION Engine oil pressure sensor Oil pump to crankcase fixing screws Filter cartridge sealing cover fixing screw 5.907.38 ftlb 7,38 ftlb 18,44 ftlb

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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