MOTO GUZZI V1000 G5 Instruction manual

oRHSHoP MANUAL
COD. 1792 01 61

Tha illustrations and duc.lptions In this manual .re indicative only. tha manulecturar """"ng 1t .. 11
the .Ight to Introduce without notice any modification It may daeem nac u .. ry 10. a bailer pe rfor mance
01 the motorcycle or lor constructl •• or commercial .. nOns.
GBM S.pA -MOTO GUZZI -SERVlZIO PUBBLICAZIONI TECNICHE
COD. 17920161
Pril'llfid in Italy- Centro StampalMo09nl- 400. 9195

INTRODUCTION
Purpose 01 this manual is to give the necessary instructions for overhauling and
carrying out repairs in a rational way.
All data herein contained are meant to give a general knowledge of the main
checking operations to be done when overhauling the different component groups .
To this end, the manual contains many Illustrations, drawings, diagrams. and
tables to assist
you in the stripping, checking, and assembling operations.
This manual will also be a gu idance for anybody who wishes to familiarize with
the manufacturing characteristics
of the various component parts of the V 1000 G 5
and 1000 SP models.
The knowledge of these will be an essential factor for performing a good job.
All illustrations and descriptions in this manual should be intended as indicative
only as the Manufacturer reserves itself the right to Introduce
at any time pend
without prior advice any modification it may deem useful for a better perform ; e
or for any other reason of a constructional or commercial nature.
NOTE The terms .. right l> and .. left .. In \h 'e text are to be considered as Hen by
th e rider astride the machine ,

Pri nted in Italy

INDEX
1.1 Spare parts
1.2 Warranty
---
2.1 Model V 1000 G 5
2.2 Model' 000 SP
COHTRot.S AND ACCES8O/IES
3.1 Model V 1000 G 5
3.2
Model 1000 SP
4.1 Engine lubrication
4.2 Replacing the oil filter cartridge and clean ing the wire gauze
filter
4.3 Lubricating the gearbox
4.4 Lubricating the rear drive box
4.5 Fork lubrication
4.6 Lubrication of steering bearings and swing arm
5.1 Panel board· model V 1000 G 5
5.2 Ignition key -model V 1000 G 5
5.3 Panel board -model 1000 SP
5.4 Light sw i tches
5.5 Horn, turn lights and flashing light bu tt ons
5.6 Engine
starting and emergency stop button
5 .7 Easy starter lever
_17
-"
_22
3

,
5.8 Throttle control grip
5.9 Clutch contro l lever
5.10 Right front brake control lever
5.11 Twin brake control, front left and rear
5.
12 Gearshift pedal
5.13 Fuel filler cap
5.14 Fuel level
5.15 Fuel tap -V 1000 G 5 model
5.16 Fuel tap -V 1000 SP model
5.17 Electrovalve -V 1000 G 5
5
.1 8 Terminal block with fuses
5.
19 Steering lock
5 .2 0 Side stand - V 1000 G 5 model
5
.21 Side stand -1000 SP model
5.22 Steering damper - 1000 SP model
IIAINTUIANCE AND ADJUSTIIENTS
6.1 Adjusting the
clutch lever play
6.2 Adjusting the right front
brake lever
6.3 Adjusting the front left and rear brake pedal
6.S Adjusting the
steering
6.'
Adjusting the rear suspension
6.6 Adjusting the throttle control grip
6.7 Adjusting the rear wheel spokes - V 1000 GS
6.8 Adjusting the
headlight beam - V 1000 G 5
6.9 Adjusting
the headlight beam -1000 SP
6.10
Rocker clearance
6.11 Adjusting the double contact breaker
6.12 Maintenance
6.13 Cleaning the windshield
LUBRICAnON AND MAINTENANCE CHART
TORQUE WRENCH
SEmNGS
SPECIAL TOOLS FOR REPAIR SHOPS
REMOVING THE ENGINE-GEARBOX UNIT FROM THE FRAME
10.1 Introduction
10 .2 Removal
STRIPPING THE ENGINE
0 ____ _
12.1 Rocker covers
12.2 Stripping the cylinder heads
12.3 Cylinder heads
12.4 Valve guides
pog.28
_32
_.33
peg. 34
_31
--

12.5 Va lve seats
12.6
Va lves
12.1 Checking the inlet and exhaust va lve opening
12
.8 Inspecting the valve springs
12.9 Refitting Ihe valve springs assembly on heads
12.10 Assembling the cylinder barrels
12. 11 Refitting the cylinder heads on the cylinders
12.12 Cylinder barrels
12.13 Pistons
12.14 Piston rings and oil scraper
12.15 Connecting rods
12.16 Fitting the
con·rods on crankshaft
1
2. 11 Crankshaft
12.18 Checking the weight
for engine balancing
12.19 Fitting the fl
yw heel on the crankshaft
12. 20 Drive side flange complete with main journa l
12 . 21 Seal for flange. drive side
12 . 22 Fitting the flange c/w jou rnal in crankcase, drive side
12.
23 Assembling the seal on timing cover
12.24 Crankcase
12.25 Checking oil leakages from the crankcase
-
~.-:=..- - ,- ..
~ ......... ~- "
. --. . --
13.1 Timing data
13.2 Diameler of camshaft bearings In their housings in crankcase
13 .3 Tappet-guide in crankcase * coupling data
13 .4 Assembling the crankshaft assembly, gears with chain on shaft.
engine*timing. oil pump
13.5 How to change the chain andl
or gear with engine assembled
on the frame
13 .6 Valve timing
•••
14.1 Oi l deliver pump
14.2 Oil sump
14
.3 Replacing the oil filter cart ridge
14.4 Wire gauze filter
14.5 Oil pressure relief va l ve
14.6 Oil breather valve on the crankcase piping to Ihe re*cycling
device on filler ass.y
14 .7 Oil pressure solenoid
14.8 Checking the oil pressure wilh engine on the byke
15 -.- ~
15.1 Carburettors
15.2 Float levelling
15.3 Adjusting the carburation and idling speed
5

6
15 .4 Checking carburation with a vacuometer
15.5 Carburetlor components
15 .6 Replacing the air filter cartridge on assembled engine
16.1 Removing the clutch assembly
16.2 Inspections
16
.3 Assembling the clutch on flywheel
~ ... ___ ..--.. • ...., ~ .. ! _~. I- --'- . '. -. . Ii"
. ~. .~. . '.
17 "-N ....... _l! " ..• $. ...... _. _-~~.
17.1 Stripping the gearbox
17.2 Checking and overhauling the gearbox components
17 .3 Assembling the gearbox on the bench
18.1 Removing the gear drive box
18.2 Inspections and overhauls
18.3 Re-assembly
... SUIF •••
FRONT 811 __ STEERING
22.1 Inspection
22.2 Removing the bearings from the swing fork
22 .3 Pressing the outer races 01) the swing arm taper be"lrings
22 .4 Pressing the bearings into the R/H arm of the swing fork
22 .5 Adjusting the swing arm play
23 .-;;
23.1 Removing the front wheel- V 1000 G 5 model
23.2 Removing the front wheel -1000 SP model
23.3 Rear wheel - V 1000 G 5 model
23 .4 Rear wheel- 1000 SP model
23.5 Tires
23 .6 Tensioning the wheel spokes - V 100 G 5
23.7 Wheel balancjng
23.8 Tira rClmoval and refitting - V 1000 G 5
23.9 Tire removal and refilling -1000 SP
23.10 Checking and overhauling the braking circuits
23 . 11 Master cylinder for ri ght front brake
--
pog. -
_1111

23 .12 Mast er cylinder for left front and rear brakes
23 .13 Brake caliper for front brakes (model V 1000 G 5) a nd r ear bra-
kes (model 1000 SP)
23 .14 Front brake caliper for 1000 $P model
23 .15 Brake pads
23 .16 Pipes
23 .17 Braking discs
23 .18 Braking circuit faults
23 .19 Recommendations
-J;;; - . - .... - . . •
24
··,.·-'······· -.'
. . .
-" -
. .
24.1 Battery
24.2 Alternator-generator
24.3 Re
gu lat or
24 .4 Rectifier
24.5 Starter
motor
24.6 Ignition system
24.1 Automatic advance
24 .8 Capa citors
24.9 Ignition coils
24 .10 Spark plugs
24.11 Twin contact breaker
24. 12 Assembling the breaker on the crankcase
24.13 Ignition timing
24 .14 Checking the i gnitio n advance (static + dynamic) using robe
lamp
24 . 15 Lighting equipment and horns - V 1 000 G 5
24.
16 Lighting equipment and horns - 1 000 SP
25 .1 Legend - V 1000 G 5 model
25.2 Legend · 1000 SP model
7

8

9

;0

a IDENTIFICATION DATA
(fig. 1)
Ev ery motorcycle is identified by an identification
prate located on the frame
downtube and a serial
number stamped on the engine crankcase. The iden-
tification plate number is also mentioned in the mo-
torcycle logbook and identifies the vehicle to all legal
effects .
1.1 SPARE PARTS
In case of any replacements, ensure thai "Original
Moto Guzzi Spare parts .. only are used.
The use of non-genuine parts invalidates every war-
ranty right.
1.2 WARRANTY
The warranty is valia fo r a period of 6 months with a
limitation to 10.000 kl\, (6000 miles) from the selling
date and expires in case of modifications to the mo-
torcycle or partecipation to racing competitions.
Tyres as well as parts or accessories which are npt
manufatured in the SE I MM MOTO GUZZI factories
are excluded from this warranty.
11

II MAIN FEATURES
2 .1 MODEL V1000 G 5
Eng"'.
Valve gearing
Carboratlon
lubr iC lllllo n
Gen era tor-alternator
Ignition
Starting
TRANSMISSIONS
Clutch
Primary drive
12
2-cylinder, 4-stroke
Cylinder dispos ition .. V ,., go '
Bore 88 mm
Stroke 78 mm
Displacement 948.8 cc
Compression ralio 9.2 to ,
Max torque 8 .6 kgm at 5200 rpm
OHV, push rod operated
2 Dell'Orto
carburettors VHB 30 CD (right), VH B 30 CS (left).
Pressur
e, by gear pump.
Wire gauze and cartridge fillers in oil sump .
Normal l ubri cation pressure 3.8 + 4.2 kg/ sqcm (54-60 p.s.i.).
Controlled by pressure relief valve.
Front, on
crankshaft (14 V-20 A),
Battery-coil ignition with twin contact breaker and automatic
advance.
Ignition dala:
• initial advance (fixed) 2'
• automatic advance 3' ·
• full advance {f . + a.J 33 "
Contact points gap: 0. 37 + 0.43 mm (.014-.016).
Spark plugs: AC -
44 XL
Bo sch W 225 2T
Champion N 9 Y
Lodge HLNY
Marelli CW 7 lP
Plug pOints gap: 0.6 mm (. 023 ")
2 ignition coils
Ele ct ric starter (12 V~ . 7 KW) with electromagnetic ratchet cont rol.
Ring gear bolted on the lIywheel.
Starter button (START) on the right sIde 01the handlebar.
Dry type, twin
pl ates. Hand controlled by lever on the left side of
the handlebar.
By gears. Ratio: 1.235 (Z =
17 / 21)

Gear box
Secondary drive
FRAME
Wheels
Tyres
Brakes
Dimensions and weig ht s
Pe rf ormances
Five·speeds. Constant mesh gear with frontal engagement incor·
porating cush drive .
Pedal controlled from the UH side of the vehicle . Gear r atios:
1st gear
2nd gear
= 1 : 2 (14128)
= 1 : 1.388 (1S /25)
3rd gear = 1 : 1.047 (21 / 22)
4th gear = 1 : 0.869 (23 / 20)
High gear = 1 : 0.750 (2S / 21)
By cardan shaft and bevel gear set.
Ratio: 1 : 4
.71 4 (7 /33)
Overall ratios (engine·rear wheel)
1st
gear = 1 : 11.643
2nd
gear
3rd gear
4th gear
High gear
~
~
~
~
1 B. OBO
1 6.095
1 5.059
1 4. 366
Duplex cradle, tubular structure.
Spoked rims, WM 3/2.15
-18"
Fr ont: 100/90 H lS (MT 18)
Rear: 110/90 H
18 ( MT IS)
Tyre pressure:
Front,
solo riding or with pillion 2.1 kg/cm2 (30 Ibs s .L ).
Aear,
solo riding 2.4 kg / cm~ (34 p.s.i.)
with
pillion 2.6 kg / cm' (37 p.s.i.).
The above figures apply
for normal riding (cruising). If using the
motorcycle at constant high speed or on highways, it is recommen·
ded to increase pressure by 0.2 kg/ cm' (3 p.s.i.).
Front: twin
disc brake, fixed caliper with two cylinders. Hand can·
trolled by lever on the right hand side of the handlebar . Braking
circ uit independent from rear brake.
Disc 0 300 mm (11.S").
Cylinder dia . 38 mm ( l.4S ").
Master cylinder dia . 12 .7 mm (.5").
Rear: Disc brake , fool conlrolled from the right side ( ~ .e motor-
cycle. Double cyli nder caliper and hydraulic hose.
Disc
dia . 242 mm (9.52").
Cylinder dia. 48 mm (1.49").
Master cylinder dia. 15.857 mm (. 63").
The rear brake is hydra ulically connected to a second front brake
of same type and sizes as the hand operated front brake .
Wheelbase 1.470 m (58")
Length 2.200 m (88.5")
Width 0.850 m (33")
Height
1.100 m (46")
Ground clearance 0.175 m (6.9")
Ground clearance 0.175 m (6.8")
Dry
weight abt. 220 kg (485 Ibs)
T op speed, solo riding abl 190 km /h (120 m.p.h.).
Fuel consumption : 5,S Its x 100 km (ab!' 36 m.p.g.).
13

FUEL AND Oil CAPACITIES
Group or part
Fuel tank
Reserve (warned by light)
Oil sump
Gear box
Rear drive box
(bevel gear lubrication)
Front
fork (each leg)
Braking circ uits (front and rear)
2.2. MODEL-ODO SP
Engino
Valye gearing
Carburation
lubrication
Generator-alternator
Ignition
14
Quantity Recommendation
24 Its. (6.5 US gl s. ) ! Petrol
98 /100 NO - RM
4 115 . (ab!. 1 US gl.)
3115 . (abt. 31 /. qts US) Oil
.. Aglp Sin! 2000 SAE 10 W/ 5O,.
0.750 Its. (abt. 25 oz. U S) Oil .. Agip F. 1 Rolra MP SAE go "
0. 250 Its. (81 12 oz.)
of which
0.230 Its. (8 oz.) Oil .. Agip F. 1 Rotra MP SAE 90.
0. 020 Us . (1 /2oz.) I
Ag ip Ro col ASO/R oil
Molikole oil type A
0. 080 Its. (2 oz.) Aglp F. 1 ATF Dexron
Agip F. 1. Brake fluid
9AE J 1703 B
Two-cylinder, 4-slroke
Cylin der disposition .. V ", 90 "
Bore 68 mm
Str oke 78 mm
Displacement
948 ,8 cc
Compression ratio 9.2 to 1
Max torque 8.6 kgm at 5200 r.p.m.
OHV, push rod operated.
2 Dell'Orto carburettors VHB 30 CO (right) VHB 30 CS (left).
Pressure, by gear pump.
Wi re gauze and cart ridge lilters in oil sump.
N
or mal lubrication pressure 3.8 -+ 4.2 kglsqcm (54-60 p.s.i.).
Controlled by pressure relief valve.
Fron
t, on crankshaft (14 V - 20 A) .
Battery-coil ignition with twin contact breaker and automatic
advance.
Ignition data:
• initial advance (fixed 'Z'
• a ut om atic advance 31"
• full advance 33·
Contact breaker gap : 0.37-0.43 mm (.014 +- .016").
Spark plugs: AC-44 Xl
Bosch W 225 T 2
Marelli CW 7 LP

Starting
TRANSMISSION
Clutch
Primary drive
Gear box
Secondary drive
FRAME
Wheels
Tires
Brakes
Champion N9 Y
Lodge HLNY
Plug points gap: 0.6 mm (.023")
2 ignition coils
Electric starter (12 V ~ 0 .7 KW) with electromagnetic ratchet co ntrol.
Ring gear bolted on the flywheel.
Starter button (S TART) on the right side of the handlebar.
Dry type, twin driven plates. It is housed on the flywheel. Hand
cont rolled by lever on the Ll H side of the handlebar.
By gears. Ratio: 1 to 1 .2 35 (17 /21).
5~speeds. Constant mesh gear with frontal engagement
Cush drive incorporated. Pedal
co ntrolled on the L/H side of the
vehicle.
Gear ratio:
Low
gear
2nd gear
3rd gear
4th gear
= 1 to 2 (14/ 18)
= 1 to 1.388 (18/25)
= 1 to 1.047 (21/22)
= 1 to 0.869 (23 /20)
High gear = 1 to 0.750 (28/21)
By cardan shall, bevel gear set.
Ratio: 1 to 4.
714 (7 /33).
Overall gear ratios (en9ine~wheel):
low gear
~ 1
to 11 . 643
2nd gear
~ 1
to 8.080
3rd gear
~ 1
to 6.095
4th gear
~ 1 to 5.059
High gear
~ 1 to 4.
366
Duplex cradle, tubular structure.
Ught alloy casting. Rims WM 3/ 2. 15-18" CP 2.
Front: 100/90 H 18 (MT 18).
Rear: 110/90 H
18 (MT 18).
Tire pressure:
Front, solo
or with pillion 2.1 kg/ cm2 (JO"p.s.i.).
Rear, solo 2.4 kg/ em' (34 p.s.L).
with pillion 2.6 kg/cm2(37
p.sj.) .
The above data apply for normal riding (cruising speed).
If using the motorcycte at constant high speed or on high ways,
the above pressure should be increased by 0.2 kg/
cm
2 (3 p.s
.. .).
Disc type with double cylinder caliper. Lever controlled from the
R/H side of the handlebar. Hydraulic circuit independent from . the
rear brake.
15

Dimensions and weights
Performances
FUEl AND Oil CAPACITIES
Group or part
Fuel tank
Reserve
Oil sump
Gear box
Re ar drive box
Front fork (each leg)
Braking ci rcuits (front and rear)
16
Disc dis. mm 300 (11.8").
Cylinder dia . 38 mm (1.49").
Master cylinder dla. 12 .7 mm (.5").
Rear wheel
Disc type with
double cylind er fixed calipe r. Foot controlled from
the R/H side of the byke.
Rear brake and the
left front brake are i nterconnected by a hy-
draulic circu it actuated by the same pedal.
Disc dia. 242 mm (9.52").
Cylinder dia. 48 mm. (l . BS ").
Master cylinder dia. 15.657 mm (.62").
The rear brake is hydraucally connected to a second front brake
of same type and sizes as the hand operated front brake.
Wheelbase (loaded) 1.460 m (58")
length 2. 180 m
(B6 ")
Width 0.750 m (29.5")
Width (i ncl. windshield) 1. 380 m (54")
Min. ground clearance 0.175 m (6.9")
Ory weight abt. 210 kgs. (463 Ibs)
Max speed, solo riding abt. 200 km/h (125 m.p.h.).
Fuel consumption: 5.6 lis X
100 km (36 m.p.g.).
Quantity Recommendation
24 Its. (6.5 US gls .) ! Petrol 96/100 NO-RM
4.lts. (a bt. 1 US gl.)
3 Its. (abt.31/1 qts. USA) Oil Agip SINT 2000 SAE 10 W/ 50
0. 750 Its. (25 oz. US) Oil Agip F. 1. Rotra MP SAE 90
0.250 lis. (ab t. 61 / ~ oz.)
of dhich
0.230 Its. (6 oz.)
Agip F. 1 Rotra MP SAE 90
0. 20 Its. e/ :;: oz .)
Agip Rocol ASO/R oil
0.090 Its. (abt. 3 oz. )
Molikote oil type "A,.
Aglp F. ATF Oexron
Agip O. 1 Brake fluid SAE J 1703 B

II CONTROLS AND ACCESSORIES
3.1 MODEL V 1000 G 5 (fig, 2)
1 Caliper. r ight Ir ont brake
2 T ur n light indicator, fr ont
3 Panel with warning lights
4 Speed ometer
5 Reservoir (masler cylinder ). right fr ont brake
6 Lever, righllront brake
7 Starter and emergenc y stop button
8 Thr otlle contro l gr ip
9 Ugh t and ignition key switch
10 Rev counter
11 Pedal, left front and rear brakes
12 F oo t r es t
13 Reservoir ( master cylinder ), lelt front and rear
brakes
14 Footrest, pi llion
15 Safely bar, rear
16 Saddle bag
17 Calipe r, left front brake
18 Headlight
19 Clutch lever
20 Safety bar, front
21 Buttons controlling horn, flashi ng lights, and turn
si gnal li ghts
22 Light switch
23 lo ck, filler cap cov er open ing
24 Easy start contro l lever
2S Gear selector pedal
26 Calip er , rear brake
27 Turn signal indicator, rear
1 2 3 4 5
\
678910 11
I 12
17 18 19
20
21 2223 24 25
13 14 15 16
\ ~
26
i
/
27
L- __________________ __ ____________________ ____ ________ ______ __ ~2
17

12 3 4
13 14 15 16
567 8
3.2 MODEL 1000 SP (fig. 3)
1 Caliper, fight front brake
2 Speedometer
3 Voltmeter
4 Rear view mirror
5 Lever. right front brake
6 Throttle control grip
7 Start and emergency stop button
8 Front fairing
9 Pedal, left front and rear brakes
10 Footrest
11 Pillion footrest
12 Turn signal indicator, rear
13 Caliper, left Irani brake
14 Rev-counter
15 Clock
16 Windshield
17 Clutch lever
18 Control buttons (horn, flashing lights, turn signal)
19 Light switch
20 Ignilion key
21 Lock, fuel filler cap cover
22 Gear selector pedal
23 Center stand
24 Tail light
25 Saddle release catch
9 10 25 11 12
1718 19 20 21 22 23 24
3 L- ________________________________ ~~--------------~
18