MOTO GUZZI MGS-01 Corsa Instruction manual

Minibook
1

Minibook
2
SUMMARY
0FOREWORD............................................................................................................................................. 3
2GENERAL FEATURES............................................................................................................................. 4
5MAINTENANCE AND SETTINGS ............................................................................................................ 5
5.7.1 CHANGING THE AIR FILTER ............................................................................................................... 5
7TIGHTENING TORQUE SETTINGS ........................................................................................................ 6
11 ENGINE UNIT ........................................................................................................................................... 7
11.2 REFITTING THE ENGINE............................................................................................................................... 7
11.3 CAM TIMING ................................................................................................................................................... 7
11.4 INSPECTIONS ................................................................................................................................................ 8
12 INJECTION – IGNITION SYSTEM ......................................................................................................... 14
12.1 INTAKE AIR CIRCUIT ................................................................................................................................... 14
12.3 FUEL CIRCUIT .............................................................................................................................................. 14
12.4 AIR CIRCUIT ................................................................................................................................................. 14
12.5 ELECTRIC CIRCUIT ..................................................................................................................................... 15
12.6 CALIBRATION STANDARDS FOR CHECKING AND SETTING CARBURETION ....................................... 15
12.11 FUNCTION OF THE "CHECK LAMP" FOR FAULT DIAGNOSIS.................................................................. 16
12.12 CONTROL UNIT RESET PROCEDURE ....................................................................................................... 16
12.13 SPARK PLUGS ............................................................................................................................................. 16
12.14 FUEL VAPOUR RECYCLING SYSTEM........................................................................................................ 16
13 CLUTCH.................................................................................................................................................. 17
14 GEARBOX .............................................................................................................................................. 17
15 REAR TRANSMISSION SHAFT AND BOX............................................................................................ 17
21 BATTERY................................................................................................................................................ 18
21.1 BATTERY ...................................................................................................................................................... 18
PROCEDURE FOR ROAD RUNNING-IN ....................................................................................................... 19
SCHEDULED MAINTENANCE ....................................................................................................................... 20
www.guzzitek.org - Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

Minibook
3
0 FOREWORD
NOTE The content of this Manual is not binding and GUZZI reserves the right to make alterations, if and when required,
of components, accessories, tooling, etc. which are deemed suitable for the purpose of improvement or for any technical
- commercial requirement, or in order to comply with law provisions in the different countries, without however
undertaking to promptly update this Manual.
- The purpose of this manual is to give the necessary instructions to rationally carry out the overhaul and repair
operations.
- The mentioned data are specified to give overall knowledge of the main inspections to be carried out while
overhauling the various assemblies.
- For this reason, the manual contains pictures, drawings and diagrams, necessary for the operations of removal,
inspection and installation.
- The manual is also a guide for the people who want to know the parts of the vehicle under exam: knowing these
parts is an essential feature for doing a good repair job.
NOTE The following information should be intended as variant to the Workshop manual - engine - for version V10
Centauro.
First edition: February 2005
Produced and printed by:
DECA s.r.l.
via Vincenzo Giardini, 11 - 48022 Lugo (RA) - Italy
Tel. +39 - 0545 246610
Fax +39 - 0545 32844
E-mail: [email protected]
www.decaweb.it
On behalf of:
Moto Guzzi s.p.a.
via E.V. Parodi, 57- 23826 Mandello del Lario (Lecco) - Italy
Tel. +39 - 709111-0341
Fax +39 - 709220-0341
www.motoguzzi.it
www.servicemotoguzzi.com
www.guzzitek.org - Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

Minibook
4
2 GENERAL FEATURES
ENGINE
Bore 100 [mm]
Stroke 78 [mm]
Total displacement 1225 [cu. cm]
Compression ratio 11.6 : 1
Maximum torque 112 [Nm] (11.4 [Kgm]) at 6400 [rpm]
Maximum power 90.2 [Kw] (122.7 [HP]) at 8000 [rpm]
TIMING SYSTEM
Overhead camshaft and 4 valves per cylinder.
Primary control with duplex chain, automatic tensioner and toothed belt.
For the primary chain installation and setting data, see version V11.
Timing system data (referred to tappet lift of 1 [mm]) are the following:
Intake
opens at 36° before TDC
closes at 69° 30' after BDC.
Exhaust
opens at 64° before BDC
closes at 38° after TDC.
Operating clearance with cold engine
intake valve 0.10 [mm]
exhaust valve 0.15 [mm]
LUBRICATION
There is no thermostatic valve.
GENERATOR
See model V11
TRANSMISSION
Primary transmission With gears, ratio 1:1.55 (Z=20/31)
Ignition Spark plug: Champion RA59GC
Gearbox The following information should be intended as variant to the Workshop
manual - gearbox - for version V11
With six speeds, with constant mesh gears and front clutch dogs.
Integrated cush drive damper.
Control through a pedal on vehicle left side.
Final transmission The following information should be intended as variant to the Workshop
manual - rear transmission shaft and box - for version V11.
Total ratios (engine wheel)
1st gear 1:10.821 (Z=15/36)
2nd 1:8.017 (Z=18/32)
3rd 1:6.150 (Z=22/30)
4th 1:5.009 (Z=27/30)
5th 1:4.355 (Z=29/28)
6th 1:3.841 (Z=27/23)
PERFORMANCE
Maximum speed 255 [km/h]
TOP-UPS
Engine sump
Oil type: AGIP Racing 4T 5W40
Quantity: 3.5 [l] check level
Gearbox
Oil type: AGIP Rotra MPS 85W90
Quantity: 0.85 [l] check level
Bevel gears
Oil type: AGIP Rotra Truck Gear 85W140
Quantity: 0.37 [l] check level
www.guzzitek.org - Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

Minibook
5
5 MAINTENANCE AND SETTINGS
5.7.1 CHANGING THE AIR FILTER
Diagrams 05-12 and 05-13 are no longer valid.
See update
www.guzzitek.org - Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

Minibook
6
7 TIGHTENING TORQUE SETTINGS
Description Q.ty Measurement Torque
Nm Note
ENGINE
Nuts for head-cylinder linkages, thread lubricated with SAE
85W90 oil M10 32-35
Nut for support securing stud bolt M8 28-32
Spark plugs
Drilled screws securing the head oil delivery hoses M10x1.25 18-20
Head temperature sensor box M10x1.25 12-15 (Loctite 648)
Head temperature sensor M12x1.25 12-15 (Loctite 243)
Screw securing crankshaft flanges M8 25-28 (Loctite 243)
Bolt securing con-rod cap, thread lubricated with SAE 85W90 5/16 UNF 57-62
Screws securing flywheel/crankshaft M8 42-45 (Loctite 243)
Screws securing flywheel crown M6 18-20 (Loctite 243)
Nut securing crankshaft sprocket M25x1.5 120-125
Generator locking nut M16x1.5 60-65
Nut securing shaft pulleys M16x1.5 115-120 (Loctite 243)
Nut securing camshafts pulleys M14x1.5 70-75 (Loctite 243)
Nut securing oil pump gear M8x1 22-25 (Loctite 243)
Oil pressure regulating valve M14x1.5 65-70 (Loctite 648)
Cam housing bushing screw M6 12-15 (Loctite 243)
Screws securing intake manifold lugs M6 12-15 (Loctite 243)
Crank pin plug on crankshaft M24x1.5 20-22 (Loctite 648)
Breather fitting from timing chain area M22x1 30-35 (Loctite 243)
Breather nozzle from heads M10x1 10-12 (Loctite 243)
Nut securing piston coolant nozzles M10x1 10-13 (Loctite 243)
Double screw securing oil nozzle hoses M10x1 10-12
Oil filter 15-20
Oil filter plug 40-45
Stud bolts tightening
Cylinder/head stud bolts on crankcase M10 32-35
Crankcase/gearbox stud bolts M8 28-30
Support/head stud bolts M8 28-30
Stud bolts securing exhaust to head M8 28-30 (Loctite 648)
Gearbox
Primary shaft ring nut on clutch side M25x1.5 100-105 (Loctite 648)
Primary shaft ring nut on cardan joint side M20x1 75-80 (Loctite 648)
Gearbox secondary shaft nut M17x1 90-95
(Loctite 648 on
spline and
thread + riveting)
Lower setting bushing (snug only) M20x1.5 10
Setting bushing locking ring nut M20x1.5 50-55
Screw securing linkage under gearbox M10 50-55
Bevel gears
Nut securing sprocket to bevel bearing 190-195
Fastening screws for cardan joint to transmission shaft M8 40-45
www.guzzitek.org - Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

Minibook
7
11 ENGINE UNIT
11.2 REFITTING THE ENGINE
- Diagram 11-32 page 78: holes Dand Eare no longer there; alignment should be obtained by matching oil
delivery holes to the main bearings.
- Diagram 11-34 page 79: is no longer valid; following is the updated version.
Vehicle, view from front:
D B
B
A
A A A A
C C
C
B
A
A : M6 x 35
B : M6 x 25
C : M8 x 45
D : M6 x 45
C
11.3 CAM TIMING
Condition
- Engine assembled up to the buckets (no rocker arms).
- Camshaft driving pulleys free to turn on the shaft.
Reference position:
Conventions:
- Right and left cylinder, with engine set in the riding direction
- Crankshaft rotating counter clockwise, looking to the clutch
- Camshaft rotating in the opposite direction with respect to crankshaft
- Timing to be performed with no rocker arms; the indicated movements are to be meant as measured on the
buckets, preloaded with their load
Left cylinder:
1LH) Left cylinder at TDC
2LH) Left camshaft in position with valves closed
3LH) Lay shaft with "notch" facing the timing sensor. This notch was made on the facing of the lay shaft threaded end.
4LH) Turn the crankshaft by 69°30’ in the direction opposite to operating direction of rotation.
5LH) Turn the camshaft in the operating direction of rotation up to the intake closing position, then turn in the opposite
direction until reaching a lift of 1 [mm].
6LH) Insert the nonius to measure pulley / cam coupling without moving the positions set for crankshaft and camshaft.
www.guzzitek.org - Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

Minibook
8
Right cylinder:
1RH) From position 1S) turn the crankshaft by 270°, in the operating direction of rotation, thus taking the right piston
to TDC.
2RH) Right camshaft in position with valves closed
3RH) Turn the crankshaft by 69°30’ in the direction opposite to operating direction of rotation.
4RH) Turn the camshaft in the operating direction of rotation up to the intake closing position, then turn in the
opposite direction until reaching a lift of 1 [mm].
5RH) Insert the nonius to measure pulley / cam coupling without moving the positions set for crankshaft and
camshaft.
11.4 INSPECTIONS
Heads
Diagram 11-63 is to be updated as follows:
Intake Exhaust
7.000 7.022
6.972 6.987 6.965 6.980 mm
35,9
45˚ 45˚ 15' 36,1
13.094 13.105mm
30,9
45˚ 45˚ 15' 31,1
53.800 54.200
www.guzzitek.org - Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

Minibook
9
Valve seats
Diagram 11-64 is to be updated as follows:
Detail of exhaust valve seat
27
28,3 28,6
6˚
90˚
30,4 30,6
Detail of exhaust valve seat
32,5
33,46 33,66
15˚ 90˚
34,98 35,18
Timing data
- The timing diagram 11-67 on page 89 is no longer valid, please refer to timing values specified in chapter 2.
www.guzzitek.org - Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

Minibook
10
Checking cylinder wear
The diagram for cylinders / pistons inspection, i.e. 11-77, is to be updated as follows:
99,92 99,95
50
20 55
- There is no class division.
- The cylinder dimensions should be between:
2nd Measurement DN = 100 – 100.02
1st Measurement DN 0 / -0.01
3rd Measurement DN + 0.01 / 0
- Clearance measured at the 2nd measurement, should be between 0.056 / 0.085.
Pistons
Diagram 11-78 is to be updated as follows:
100
22
0,40+0,65
54,5-8,05
1,19 1,21
0,30 0,60
1,21 1,23
2,51 2,53
22,01 22,005
-0,006
-0,002
- The piston is to be installed with the "small" valve pockets on the exhaust side
1s
t
Measurement
2nd Measurement
3rd Measurement
www.guzzitek.org - Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten