MOTO GUZZI MGS-01 Corsa Instruction manual

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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
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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
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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
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5 MAINTENANCE AND SETTINGS
5.7.1 CHANGING THE AIR FILTER
Diagrams 05-12 and 05-13 are no longer valid.
See update
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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
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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.
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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
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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.
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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
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Connecting rods
Diagram 11-80 is to be updated as follows:
CARRILLO Connecting rod
22,035 22,055
143,95 144,05
22,4
23,825
23,775
47,13 47,14
22,6
- Diagram 11-80/A: the value 47.13 – 47.14 for bearing bore is no longer valid.
- Con-rod bearings thickness: no bearing with oversized thickness is available.
- Crank pin diameter: only the standard size is available.
Values for gudgeon pin and bushing clearance:
Installed bushing inside diameter: 22.035-22.055 [mm]
Gudgeon pin diameter 21.994-21.998 [mm]
Clearance 0.037- 0.061 [mm]
- Assembling the connecting rods to the crankshaft: tightening to 8.5-9.3 [kgm] is no longer valid; see Torque
figure table.
Crankshaft
- No undersizes are available.
- Checking the weight for crankshaft balancing: no checks for balancing are scheduled outside the parent
company.
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Thermostatic valve
- Diagram 11-89 page 98 is no longer valid; no thermostat is to be installed.
A pressure reducing valve is installed, opening at 5.5 [bar].
Diagram 11-94 is to be updated as follows:
Diagram of the blow-by and piston cooling circuit
The sump layout is the same as the Centauro one
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Timing system
- Table 4: Update of the primary timing as in Breva 1100 version.
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12 INJECTION – IGNITION SYSTEM
12.1 INTAKE AIR CIRCUIT
- The absolute pressure sensor is integrated in the control unit.
- The "N.B" indication for the air temperature sensor position is no longer valid.
- The air temperature sensor is positioned in the filter box.
- Starting stage: no mixture enrichment is set depending on oil temperature, only depending on head
temperature.
12.3 FUEL CIRCUIT
Fuel electric pump
- Feeding pressure 4 + - 0.2 [bar] , measured at AA
Fuel filter
- Integrated in the module inside the tank.
AA
12.4 AIR CIRCUIT
- Diagram 12-04 is no longer valid. See air filter change diagram
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12.5 ELECTRIC CIRCUIT
- Diagram 12-05 is no longer valid.
Air
Temperature
Sensor
Diagnostic socket
Speedometer sensor
Electronic control unit I.A.W. 16M
- Superseded by I.A.W. 15M
12.6 CALIBRATION STANDARDS FOR CHECKING AND SETTING CARBURETION
Setting
•Vehicle off - key ON.
•Connect the diagnosis tester “Axone” to diagnostic socket and vacuum gauge.
•Remove the right throttle body rod.
•Using the throttle adjuster dowel, set throttle position sensor -on right throttle body- to 2.9°/3°.
NOTE Turn the key to off before disconnecting the throttle position sensor.
•Start the engine and take engine temperature at least to 50° (engine temperature is the temperature reading taken
with “Axone”)
•Completely close the by-pass screws
•Connect the throttle body rod, check that the throttle body on TPS side is fully home, then ensure -not at idle speed
(2000/3000 RPM)- that vacuum is balanced in the two cylinders. In case of unbalance, work the wing nut of the
linkage to balance the two throttle bodies.
NOTE Disconnect the vacuum gauge.
NOTE From this step on, the engine temperature should be between 70° and 80° (in any case, let the engine run for at
least 3 minutes before checking the CO)
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•Using the by-pass screws, set idle speed at 1450 +/-50 rpm.
NOTE After this procedure, if idle speed does not fall within recommended range, check the throttle position sensor by
inserting the suitable cable connected to the digital tester and closing the throttle completely on the duct (throttle angle:
0°). The tester reading should be 150 mV +/-15 mV; if not, reposition the throttle sensor until reading 150 mV and report
the problem to the quality manager.
•Using the control unit trimmer, set the CO to 4% +/-0.5.
NOTE The Trimmer value can be set to any value as far as it allows you to reach the desired CO level.
•Check that the CO of the right cylinder is at the same level as in the left cylinder (+/- 0.2); if not, take the CO value
within the specified range using the right By-pass screw.
Setting summary sheet
Throttle position at idle speed 2.9° /3° (+/- 0.1)
By-pass setting Balance the two cylinders, approx. 1 turn (the value can be different on any
motorcycle)
Nominal rpm at idle speed 1450 tolerance +/-50rpm
with vehicle warm at least at 80°C
CO value at exhaust 4% tolerance +/-0.5
NOTE Finally balance the CO level in both cylinders using the by-pass screws.
12.11 FUNCTION OF THE "CHECK LAMP" FOR FAULT DIAGNOSIS
- Not set.
12.12 CONTROL UNIT RESET PROCEDURE
- Functions 12.11 and 12.12 are realised through the same procedures specified for the V11 Sport version.
- The manual concerning the tool that can communicate with the control unit is available on www.servicemoto.it
12.13 SPARK PLUGS
- Spark plug Champion RA59GC
12.14 FUEL VAPOUR RECYCLING SYSTEM
- No vapour recycling system is foreseen.
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13 CLUTCH
Clutch springs
- A 1 [mm] shim is to be installed under each spring, on crankshaft side.
14 GEARBOX
- See model V11
15 REAR TRANSMISSION SHAFT AND BOX
- See model V11
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21 BATTERY
21.1 BATTERY
The battery's voltage is 12 V with a capacity of 13 Ah; it is charged by the generator.
The battery used on the motorbike is a sealed type battery (without maintenance) which does not require any checks.
Charging instructions
NOTE It contains toxic substances (Pb and H2 SO4); extremely high currents, avoid short circuits; do not recharge in the
sealed container; using different battery chargers will cause irreparable damage to the battery.
General notes
Charging pure-tin sealed accumulators, just as other re-chargable accumulators, is a matter of saving the energy
supplied during discharge. As this process is in some ways inefficient, it is necessary to bring back to the accumulator
from 105% to 110% of the amperes-hour supplied during discharge. The quality of the power necessary to completely
recharge the battery depends on the flatness of the accumulator, on the method, recharging time and temperature.
It is important that the battery is capable of supplying all or nearly all of its capacity before receiving the required over-
charging. However, to obtain an optimal duration in terms of cycle numbers, the battery must periodically receive the
required over-charging.
Charging can be carried out in different ways.
The aim is to convey current through the battery in the direction opposite to the discharge. Constant voltage charging is
the standard method used to charge lead acid typeaccumulators.
Constant voltage charging:
The voltage charging method is the most efficient for charging sealed lead- acid pure-tin accumulators.
Using
this charging method, it is not necessary to limit the maximum current supplied by the charger. The voltage must
however be adjusted so that it is within the values prescribed below. This feature is due to the internal resistance of the
battery. It is extremely low and features a high recombination efficiency during charging. We recommend to observe the
following values for constant voltage charging:
Cyclic use:
•from 14.7V to 15.0V for battery at 25°C. No current limit requested.
Buffer use:
•from 13.50V to 13.80V for battery at 25°C. No current limit requested.
Removal:
•Remove the fairings;
•Release the locking belt;
•Disconnect the negative terminal, then the positive one by unscrewing the nuts;
•Remove the battery from the motorbike.
NOTE Always disconnect the negative terminal first then the positive one.
NOTE The negative terminal is black, while the positive one is red.
Refitting:
•Apply protective spray for electrical contacts on the battery terminals;
•Insert the battery in its seat on the motorbike;
•Connect the positive terminal then the negative one;
•Hook the locking belt once again.
•Refit the fairings.
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PROCEDURE FOR ROAD RUNNING-IN
Correct engine running-in is essential to ensuring proper performance and durability.
Follow these recommendations:
•Warm up engine oil over 50°C (the instrument panel alarm goes off)
•Vary speed frequently during the running-in period.
•First step: run 20 Km, engine at max. 5000 rpm, throttle max. at 40%
•After about 5 / 6 Km stop for an overall check for possible leaks or loose parts
•Second step: during the next 30 Km, never exceed 6000 rpm with throttle maximum at 50%
•For another 30 Km, take the engine up to 7000 rpm with throttle maximum at 80%
•While it is important to put some stress on engine components during running-in, it is equally important to avoid
extreme load conditions.
It is possible to obtain the best performance from your engine only after the first 100 Km, i.e. at the end of
running-in.
NOTE At this point, it is a good rule to change the engine oil and the gearbox fluid and perform an overall check of the
correct tightening of the vehicle nuts and bolts.
NOTE The table containing the mileage intervals for service coupons is to be considered after running-in
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SCHEDULED MAINTENANCE
Legend:
RCheck parts and change if they no longer meet the specifications
CChange
Pre delivery
After
Intervention
Every
Intervention
Every
Change
Engine
Nuts and bolts tightening R
Spark plugs 2000 C2000 C
Throttle body R1000 R2000 R
Throttle body (synchronisation) 1000 R2000 R
Air filter 2000 C2000 C
Oil filter 4000 C4000 C
Engine oil R4000 C4000 C
Fuel filter 4000 C4000 C
Valve clearance 1000 R2000 R
Spark plug cables 2000 R2000 R6000 C
Valve seats 4000 R4000 R12000 C"R" lap upon each inspection
Valve guides 4000 R4000 R12000 C"R" dimensional check
Head structural analysis 8000 R4000 R"R" part must be free from cracks
Camshafts 4000 R4000 R"R" visual and dimensional inspection
Retainers 4000 R4000 R6000 C"R" visual and dimensional inspection
Intake valves and collets 2000 C2000 C
Exhaust valves and collets 2000 C2000 C
Valve seals 2000 C2000 C
Valve springs 4000 C4000 C
Valve to shim clearance
adjusting screws 2000 C2000 C
Timing belt 1000 R1000 R4000 C"R" belt tension check and visual inspection
Belt tensioner bearings 4000 C4000 C"R" check for proper operation
Valve timing 4000 R4000 R"R" restore correct timing
Complete piston 1000 C1000 C
Cilinder 3000 C3000 C
Cylinder stud bolt nuts 2000 C2000 C
Head gaskets 2000 C2000 C
Oil pump 6000 R6000 R18000 C"R" visual inspection of aluminium pump body
Oil press. valve 18000 C18000 C
Exhaust pipe 4000 R2000 R8000 C"R" visual inspection for structural damage
Silencer 2000 R4000 C"R" change sound-deadening material
Timing chain 4000 C4000 C
Crankshaft 4000 R4000 R"R" visual inspection of shafts and shims
for wear and analysis with crack detector
Connecting rods
4000 R4000 R
"R" visual and dimensional inspection of piston
pin bearing and connecting rod bearings;
bearing parallelism; crack detector
Connecting rod bearings 4000 C4000 C
Crankshaft rotary seals 4000 C4000 C
Crankcase 12000 R4000 R"R" part must be free from cracks
Crankshaft bearings 12000 R4000 R"R" visual and dimensional inspection of bearings
Timing cover 12000 R4000 R"R" part must be free from cracks
Clutch
System fluid R6000 C6000 C
Clutch pushrod 6000 R6000 R"R" check for wear
Clutch plates 2000 R2000 R3000 C"R" check thickness
Gearbox
Fluid R3000 C3000 C
Primary transmission 4000 R4000 R"R" check teeth for wear and Wildaber test
Gears 4000 R4000 R"R" check teeth for wear and Wildaber test
Bearings 4000 R4000 R8000 C"R" check for proper operation
Secondary shaft nuts 2000 R2000 R4000 C"R" check nuts angle position
Transmission
Crosses 4000 R4000 R8000 C"R" check clearance and smooth movement
Complete transmission shaft 8000 C8000 C
Bevel gears
Bevel gears oil R3000 C3000 C
Gears 4000 R4000 R"R" check teeth for wear
Bearings 4000 R4000 R8000 C"R" check for proper operation
Notes
Operations that do not require removal of main engine parts
Maintenance operations that do not require removal from vehicle
Maintenance operations requiring removal from vehicle
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