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MOTO GUZZI V 35 User Manual

MOTO GUZZI V 35
114 pages
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WORKSHOP
MANUAL
COD. 19920101

Table of Contents

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MOTO GUZZI V 35 Specifications

General IconGeneral
Displacement346 cc
Transmission5-speed
Front BrakesSingle disc
Rear BrakesDrum
Cooling SystemAir
Final DriveShaft
Frame typeSteel
Front SuspensionTelescopic forks

Summary

MAIN FEATURES

MAINTENANCE OPERATIONS

ENGINE LUBRICATION

Procedure for checking and changing engine oil levels and quantities.

REPLACING THE OIL CARTRIDGE IN THE SUMP

Steps to replace the oil filter cartridge in the oil sump.

CLEANING THE WIRE GAUZE FILTER AND THE SUMP

Instructions for dismantling, cleaning, and reassembling the oil sump and wire gauze filter.

LUBRICATION OF THE GEAR BOX

Procedure for checking and changing the gearbox oil level and quantity.

LUBRICATION OF REAR DRIVE BOX

Procedure for checking and changing the rear drive box oil level and quantity.

LUBRICATION OF FRONT FORK

Steps for draining and refilling the front fork oil.

SUNDRY LUBRICATIONS

Periodic lubrication points for various motorcycle components.

CONTROLS AND INSTRUMENTS

Description of panel board indicators, warning lights, and their functions.

IGNITION KEY

Explanation of the ignition key positions and their functions.

LIGHT SWITCHES

Location and operation of the light switches on the left handlebar.

HORN, FLASH LIGHT AND TURN SIGNAL CONTROL

Operation of horn, flash light, and turn signal controls on the handlebar.

ENGINE STARTING AND EMERGENCY STOP SWITCH

Procedure for starting the engine and using the emergency stop switch.

RIGHT FRONT BRAKE CONTROL LEVER

Description of the right front brake control lever on the handlebar.

LEFT FRONT BRAKE AND REAR BRAKE CONTROL PEDAL

Location and function of the combined front left and rear brake control pedal.

GEAR CONTROL

Operation of the gear control pedal on the left side of the machine.

FUEL FILTER CAP

How to open the fuel filter cap.

FRONT AND REAR BRAKES FLUID RESERVOIR

Procedure for checking the brake fluid level in the reservoir.

FUEL TAPS

Description of the fuel tap positions (ON, RES, OFF).

TERMINAL BLOCK WITH FUSES

Location and identification of fuses in the terminal block.

STEERING LOCK

Instructions for locking and unlocking the steering.

SEAT LOCKING DEVICE

Procedure for unlocking and locking the seat.

SIDE STAND

Information on the side stand, including types and usage.

ADJUSTING THE CLUTCH CONTROL LEVER

Procedure for adjusting the play in the clutch control lever.

ADJUSTING THE RIGHT FRONT BRAKE LEVER

Procedure for adjusting the play in the right front brake lever.

ADJUSTING THE LEFT FRONT BRAKE AND THE REAR BRAKE PEDAL

Checking and adjusting play in the linkage for left front and rear brake pedal.

ADJUSTING THE THROTTLE CONTROL GRIP

Adjusting the travel of the twist grip and its return.

ADJUSTING THE STEERING

Procedure for adjusting steering to eliminate excessive play.

ADJUSTING THE SWINGING ARM PLAY

Ensuring the swinging arm oscillates freely without play.

ADJUSTING THE REAR SUSPENSION

Procedure for adjusting the external spring of the rear suspension.

ADJUSTING ROCKER CLEARANCE

Procedure for adjusting rocker clearance on a cold engine.

LUBRICATION AND MAINTENANCE OPERATIONS

Schedule of lubrication and maintenance tasks with recommended intervals.

TORQUE LOADINGS

SPECIFIC WORKSHOP TOOLS

ENGINE UNIT

REMOVAL OF ENGINE-GEARBOX FROM THE FRAME - SEPARATION OF ENGINE FROM GEARBOX

Procedure for removing the engine-gearbox assembly from the frame and separating them.

REMOVING THE ROCKER BOX COVERS

Instructions for removing the rocker box covers.

STRIPPING THE CYLINDER HEADS

Procedure for dismantling the cylinder heads, including valve removal.

REMOVING THE CYLINDER BARRELS

Procedure for removing the cylinder barrels and checking them.

REMOVING THE COMPRESSION RINGS AND OIL SCRAPERS FROM THE PISTON

Procedure for removing piston rings and oil scrapers.

REMOVAL OF PISTONS

Procedure for removing pistons from the engine, including checking operations.

SEPARATING THE CRANKCASE COVERS

Procedure for separating the crankcase covers.

REPLACING THE SEAL IN TIMING COVER (ENGINE MOUNTED)

Procedure for replacing the seal in the timing cover while the engine is mounted.

DISMANTLING THE CON-RODS

Procedure for dismantling connecting rods.

DISMANTLING THE CRANKSHAFT

Procedure for dismantling the crankshaft.

REMOVING THE FLYWHEEL

Procedure for removing the flywheel.

DISMANTLING THE IGNITION GROUP

Procedure for dismantling the ignition group.

LUBRICATION

REMOVING THE OIL SUMP

Procedure for removing the engine oil sump.

DISMANTLING THE OIL PUMP

Procedure for dismantling the oil pump.

REMOVING THE OIL PRESSURE RELIEF VALVE

Procedure for removing the oil pressure relief valve.

OIL PRESSURE LIGHT SWITCH

Function of the oil pressure warning light switch.

REMOVING THE OIL CARTRIDGE FROM THE SUMP

Procedure for removing the oil filter cartridge from the sump.

REMOVING THE WIRE GAUGE FILTER FROM THE OIL SUMP

Procedure for removing the wire gauge filter from the oil sump.

CARBURATION

CARBURETTORS

Description of the Dell'Orto carburetors and their controls.

CARBURETTOR SETTING

Specifications for carburetor settings (jet sizes, needle position, etc.).

LEVELUNG THE FLOATER

Procedure for leveling the carburetor float.

MANUAL ADJUSTMENT OF CARBURATION AND IDLING SPEED

Steps for adjusting carburetor and idling speed.

ADJUSTING CARBURATION USING A VACUOMETER

Procedure for adjusting carburation using a vacuum gauge.

STRIPPING THE CARBURETTOR

Detailed procedure for dismantling a carburetor.

AIR FILTER AND BREATHER UNIT

Components and removal of the air filter and breather unit.

CLUTCH

Removal

Procedure for removing the clutch assembly.

Inspection

Inspection of clutch components for wear or damage.

THE GEARBOX

REMOVING THE GEARBOX FROM THE FRAME AND SWINGING ARM FROM THE GEARBOX

Procedure for removing the gearbox and swinging arm.

CLUTCH HOUSING

Procedure for removing and inspecting the clutch housing.

CLUTCH

Procedure for removing and inspecting the clutch.

GEAR BOX

Procedure for dismantling the gearbox.

GEARBOX COVER

Procedure for removing and inspecting the gearbox cover.

GEAR-SHAFTS ASSEMBLY

Procedure for dismantling and reassembling the gear-shafts.

GEAR SELECTOR

Procedure for dismantling, inspecting, and reassembling the gear selector.

KICKSTARTER OPERATED MODEL (optional)

Dismantling

Procedure for dismantling the kickstarter mechanism.

Inspection

Inspection of kickstarter components for wear or damage.

SWINGING ARM COMPLETE WITH REAR DRIVE BOX

Removal

Procedure for removing the swinging arm and rear drive box.

Inspection

Inspection of the swinging arm and drive box components.

DRIVE BOX

Procedure for removing the bevel pinion housing from the drive box.

Removing the brake disc, casing cover, hollow spindle, crown wheel, bearings and seals.

Procedure for removing brake disc, cover, spindle, crown wheel, bearings, and seals.

Pinion-wheel coupling clearance (bevel set)

Procedure for adjusting pinion-wheel coupling clearance.

SWINGING ARM

Procedure for removing and re-assembling the swinging arm.

FRAME

Inspection

Inspection of frame components and electricals.

FRONT FORK

Removal from frame

Procedure for removing the front fork assembly from the motorcycle frame.

Re-assembling the fork

Procedure for reassembling the front fork assembly.

FORK SLEEVE

Procedure for removing the fork sleeve from the fork.

REAR SUSPENSION

Dismantling from the frame

Procedure for removing the rear shock absorbers from the frame.

Inspection

Inspection of rear suspension springs and shock absorbers.

STEERING

Dismantling

Procedure for dismantling the steering assembly.

Inspection

Inspection of steering components for wear or damage.

WHEELS

FRONT WHEEL

Procedure for removing the front wheel from the fork.

Removing the front wheel hub

Procedure for removing the front wheel hub.

REAR WHEEL

Procedure for removing the rear wheel from the swinging arm.

Removing the rear wheel hub

Procedure for removing the rear wheel hub.

TYRES

Information on tire types, recommended pressures, and wear.

WHEEL BALANCING

Procedure for balancing wheels when a machine is unavailable.

REMOVING AN RE-FITIING THE TYRES

Recommendations for removing and refitting tires to avoid damage.

ELECTRICAL EQUIPMENT

BATTERY

Procedure for putting a new dry battery into service.

Measuring specific gravity and temperature of electrolyte

Procedure for measuring electrolyte specific gravity and temperature.

Correction of the specific gravity reading in respect of temperature

Method for correcting specific gravity readings based on temperature.

ALTERNATOR

Main features and testing procedure for the alternator.

REGULATOR

Main features of the voltage regulator.

RECTIFIER

Brand information for the rectifier.

STARTER MOTOR

Main features and electric tests for the starter motors.

ELECTRONIC IGNITION

Information on the electronic ignition system, operation, and warnings.

Manual adjustment ollgnlUon liming

Procedure for manually adjusting ignition timing.

Adjusling ignllion timing by the aid of a special tool

Using a special tool to adjust ignition timing.

CHECKING IGNITION TIMIN1NG USING A STROBE LAMP

Using a strobe lamp to check ignition timing.

Spark plug

Recommended spark plug brands, gap, and replacement.

Headlight

Description and specifications of the headlight.

Replacement of headlight bulbs

Procedure for replacing headlight bulbs.

Tail light

Location and bulb replacement for the tail light.

Front and rear turn lights

Description and location of front and rear turn signal lights.

Panel board - Speedometer - Rev-counter

Procedure for replacing bulbs in the panel board instruments.

Bulbs (12 V)

List of bulb types and wattages for various lights.

Horn

Brand and current absorption of the horn.

Overhaul and repair of horn

Troubleshooting and repair of the horn.

Cables

Ensuring cable condition and proper accessory connections.

KEY TO WIRING DIAGRAM

INCHES AND MILLIMETERS CONVERSION CHART

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