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MOTO GUZZI V11 LE MANS MY 2003 User Manual

MOTO GUZZI V11 LE MANS MY 2003
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WORKSHOP MANUAL
WERKSTATTHANDBUCH
ONDERHOUDS-EN
REPARATIEHANDBOEK

Table of Contents

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MOTO GUZZI V11 LE MANS MY 2003 Specifications

General IconGeneral
Displacement1064 cc
Compression Ratio9.8:1
Fuel SystemElectronic Fuel Injection
Transmission6-speed
Final DriveShaft
Front Tire120/70 ZR17
Rear Tire180/55 ZR17
Bore x Stroke92 mm x 80 mm
Rear SuspensionSingle shock, adjustable preload
Front BrakesDual 320 mm discs
Rear BrakesSingle 282 mm disc
Wheelbase1490 mm
Seat Height800 mm
Engine TypeV-twin, 90°
Max Power91 hp (67 kW) @ 7800 rpm
FrameTubular steel
Fuel Capacity22 liters (5.8 US gal)

Summary

WORKSHOP MANUAL

SEC. A GENERAL INFORMATION

GENERAL SAFETY REGULATIONS

Essential safety rules and regulations for operating and maintaining the motorcycle.

RULES FOR MAINTENANCE PROCEDURES

Guidelines and rules to follow for performing maintenance procedures.

SEC. B MODEL FEATURES

IDENTIFICATION DATA

Details for identifying the motorcycle, including chassis and engine numbers.

LUBRICANTS AND REFILLING

Specifications for lubricants and fluid capacities for refilling various systems.

TECHNICAL SPECIFICATIONS

Detailed technical specifications of the motorcycle's engine, chassis, and components.

TIGHTENING TORQUES

Specified torque values for various bolts and fasteners during assembly and maintenance.

SEC. C CONTROL AND USE OF THE MORBIKE

PRELIMINARY TESTS

Pre-operation checks and tests to ensure the motorcycle is safe and ready for use.

ENGINE IGNITION

Information on the engine ignition system and its operation.

PARKING

Motorcycle parking instructions.

OPERATION DURING THE ACCELERATION STAGE

Description of system operation during the acceleration stage.

SEC. D SCHEDULED MAINTENANCE

SCHEDULED MAINTENANCE - TABLE

A table outlining scheduled maintenance tasks based on mileage intervals.

SEC. F WHEEL PARTS

FRONT WHEEL

Information specific to the front wheel of the motorcycle.

REAR WHEEL

Information specific to the rear wheel of the motorcycle.

FRONT HYDRAULIC BRAKE

Details and procedures for the front hydraulic brake system.

REAR HYDRAULIC BRAKE

Details and procedures for the rear hydraulic brake system.

FRONT FORK

Information and procedures related to the front fork assembly.

REAR SHOCK-ABSORBER

Information on the rear shock absorber and its maintenance.

STEERING SHOCK ABSORBER

Details about the steering shock absorber and its adjustment.

TIRES

Tire specifications for the front and rear wheels, including brands and sizes.

SEC. H CHASSIS

STEERING

Information related to the motorcycle's steering system.

HALF-HANDLEBARS

Details concerning the half-handlebars on these variants.

SUSPENSIONS

Details on the front and rear suspension systems.

BRAKES

Details of the front and rear brake systems, including disc size and caliper type.

SEC. I FUEL SYSTEM

GENERAL DESCRIPTION OF THE SYSTEM

Overview of the motorcycle's fuel system components and function.

SYSTEM COMPONENTS

Overview of the motorcycle's fuel system components.

TANK “3”

Specific information about the fuel tank, labeled as '3'.

ELECTRICAL FUEL PUMP “1” UNIT

Details on the electric fuel pump unit, labeled as '1'.

FUEL FILTER “2”

Information about the fuel filter, labeled as '2'.

ELECTRO-INJECTORS “3”

Details on the electro-injectors, labeled as '3'.

PRESSURE ADJUSTER “4”

Information on the pressure adjuster, labeled as '4'.

AIR FILTER BOX “1”

Procedures for removing and installing the air filter box, labeled as '1'.

THROTTLE BODY “2”

Information on the throttle body, labeled as '2'.

INTAKE AIR CIRCUIT

Description of the intake air circuit, including filter, manifold, and throttle body.

SEC. L EXHAUST SYSTEM

SYSTEM FEATURES

Overview of the exhaust system's features and design.

EXHAUST PIPES

Information about the exhaust pipes.

EXPANSION CHAMBER AND LAMBDA SENSOR

Procedures for removing and checking the expansion chamber and lambda sensor.

SEC. M ENGINE

GENERAL RULES FOR ENGINE OVERHAUL

General guidelines and precautions for engine overhaul procedures.

ENGINE UNIT REMOVAL - INSTALLATION

Step-by-step instructions for removing and installing the engine unit.

LUBRICATION SYSTEM

Explanation of the engine's lubrication system and its components.

HEADS AND TIMING SYSTEM

Details on the cylinder heads and the engine's timing system.

CYLINDERS AND PISTONS

Information regarding the cylinders and pistons of the engine.

CLUTCH

Details about the motorcycle's clutch system.

ALTERNATOR

Information on the alternator and its function.

KRANK SHAFT AND CONNECTING RODS

Details concerning the crankshaft and connecting rods of the engine.

SEC. N GEARBOX

MAIN FEATURES

Overview of the primary features of the gearbox.

REMOVAL AND INSTALLATION

Procedures for removing and installing the gearbox.

DISASSEMBLY

Step-by-step instructions for disassembling the gearbox.

REASSEMBLY

Procedures for reassembling the gearbox after disassembly.

SEC. O REAR TRANSMISSION HOUSING AND SHAFT

REAR TRANSMISSION HOUSING

Information about the rear transmission housing.

TRANSMISSION SHAFT

Details regarding the transmission shaft.

SEC. P ELECTRICAL SYSTEM

ELECTRICAL SYSTEM DESCRIPTION

General overview of the motorcycle's electrical system and its components.

BATTERY

Information and maintenance for the motorcycle's battery.

STARTER MOTOR

Details about the starter motor and its operation.

LIGHT AND ACOUSTIC SYSTEMS / DASH BOARD / CONTROLS

Description of lights, acoustic signals, dashboard, and controls.

SIDE STAND SWITCH

Information on the side stand switch.

FUSE TERMINAL BOARD

Location and description of the fuse terminal board.

ALTERNATOR AND VOLTAGE CONTROLLER

Details on the alternator and voltage controller.

SEC. Q V11 SPORT NAKED AND V11 LE MANS VARIANTS

IDENTIFICATION DATA

Motorcycle identification data for various models.

TECHNICAL SPECIFICATIONS

Technical specifications specific to Naked and Le Mans variants.

LIGHT BEAM ADJUSTMENT (LE MANS)

Procedure for adjusting the headlight beam on Le Mans models.

CLEANING THE WINDSCREEN

Instructions for cleaning the motorcycle's windscreen.

SCHEDULED MAINTENANCE - TABLE

Maintenance schedule table for Naked and Le Mans variants.

FUEL FILTER

Information and procedure for replacing the fuel filter.

WING MIRRORS (LEMANS)

Details regarding the wing mirrors on Le Mans models.

REAR FAIRING

Information about the rear fairing.

FAIRING (LE MANS)

Details concerning the fairing on Le Mans models.

HEADLIGHT FAIRING CLEAR PLATE (LE MANS)

Procedure for removing and installing the clear plate of the headlight fairing on Le Mans models.

STEERING SHOCK ABSORBER (LE MANS)

Details about the steering shock absorber on Le Mans models.

HALF-HANDLEBARS

Details concerning the half-handlebars on these variants.

ENGINE UNIT REMOVAL - INSTALLATION

Procedures for engine unit removal and installation on these variants.

LIGHT AND ACOUSTIC SYSTEMS / DASH BOARD / CONTROLS

Information about dashboard warning lights on Le Mans models.

SEZ. R VARIANTS V11 SPORT MY2003 - LE MANS MY2003 - ROSSO CORSA - CAFÉ SPORT - BALLABIO VARIANTS

IDENTIFICATION DATA

Motorcycle identification data for various models.

LUBRICANTS AND REFILLING

Specifications for lubricants and refilling procedures for various models.

SPECIFICATIONS

Detailed specifications for various motorcycle models.

PRELIMINARY TESTS

Pre-operation checks and tests for various models.

ENGINE IGNITION

Information on engine ignition for various models.

PARKING

Motorcycle parking instructions for various models.

ÖHLINS - V11 CAFE SPORT STEERING DAMPER

Details on the Öhlins steering damper for V11 Cafe Sport.

ADJUSTING THE HEADLIGHT BEAM – V11 CAFÉ SPORT – V11 BALLABIO

Procedure for adjusting the headlight beam on V11 Cafe Sport and Ballabio.

SEC. F WHEEL PARTS

FRONT FORK

Information and procedures related to the front fork assembly.

FRONT FORK - PARTS

Detailed parts list for the Marzocchi front fork assembly.

REMOVAL WITH MARZOCCHI AND ÖHLINS 2ND SERIES FORK

Procedures for removing Marzocchi and Öhlins 2nd series front forks.

REASSEMBLY WITH MARZOCCHI AND ÖHLINS 2ND SERIES FORK

Procedures for reassembling Marzocchi and Öhlins 2nd series front forks.

REMOVING THE STANCHIONS – SLIDERS

Procedures for removing stanchions and sliders from Marzocchi and Öhlins forks.

CHANGING “MARZOCCHI” FRONT FORK OIL

Procedure for changing the oil in Marzocchi front forks.

CHANGING THE ÖHLINS FORK OIL/ DUST SEALS

Procedure for changing fork oil and dust seals on Öhlins forks.

FRONT FORK OIL CHANGE “ÖHLINS”

Procedure for changing the oil in Öhlins front forks.

FILLING THE FRONT FORK “ÖHLINS”

Procedure for filling the front fork with Öhlins oil.

33 CARBURATION CONTROL, ADJUSTMENT AND SETTING PROCEDURE WITH AXONE 2000

DISASSEMBLY

Procedures for disassembling components related to carburation control.

REASSEMBLY

Procedures for reassembling components after carburation adjustments.

34 FUEL VAPOUR PURIFICATION AND RECIRCULATION SYSTEM (USA)

N.B.

Important note regarding the installation of the roll-over shut-off valve.

35 EXHAUST SYSTEM

SYSTEM SPECIFICATIONS

Overview of the exhaust system's specifications.

EXHAUST AND BALANCE PIPES

Details about the exhaust and balance pipes.

EXPANSION CHAMBER AND LAMBDA SENSOR

Procedures for removing and checking the expansion chamber and lambda sensor.

CHECKING LAMBDA SENSOR CORRECT OPERATION

Procedure for checking the correct operation of the lambda sensor.

36 GEARBOX

PRE-SELECTOR COVER

Procedures for reassembling and fitting the pre-selector cover.

SEC. P ELECTRICAL SYSTEM

ELECTRICAL SYSTEM DESCRIPTION

General overview of the electrical system and its components.

FUSE TERMINAL BOARD

Location and description of the fuse terminal board.

ELECTRIC system diagram (NON-CATALYTIC VERSION)

Wiring diagram for the non-catalytic version of the electrical system.

38 CONTROLS/INSTRUMENT PANEL/ AUDIBLE AND LIGHTING SIGNAL SYSTEM

N.B.

Note regarding the removal of headlight and instrument panel.

39 FUSE TERMINAL BOARD

CHANGING FUSES

Procedures for replacing damaged fuses, including safety precautions.

40 SHINDENGEN REGULATOR

REGULATOR CHECKS

Procedures for checking the regulator for defects using workshop tools.

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