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