Moto Guzzi Breva 1100 V 1949-2008 Manual de reparatie
00/2005-07
1247 5
UK
USA
Cod. 8140861
Cod.
workshopmanual
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INTRODUCTION
INTRODUCTION 0
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INTRODUCTION
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Breva V1100
TABLE OF CONTENTS
0.1.
INTRODUCTION .............................................................................................................................................. 3
0.1.1. FOREWORD ............................................................................................................................................. 3
0.1.2. REFERENCE MANUALS .......................................................................................................................... 4
0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS ........................................................................................ 5
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INTRODUCTION
0.1. INTRODUCTION
0.1.1. FOREWORD
This manual provides the information required for normal servicing.
This publication is intended for use by Moto Guzzi Dealers and their qualified mechanics; certain information has been
omitted intentionally, as this manual does not purport to provide a comprehensive treatise on mechanics. The persons
who will use this manual must be fully conversant with the basics of mechanics and with the basic procedures of
motorcycle repair. Repairing or inspecting a motorcycle when one does not possess such basic knowledge or training
could result in improper servicing and make the motorcycle unsafe to ride. For the same reason, certain basic
precautions have been omitted in the descriptions of repair and inspection procedures; you are therefore invited to take
special care to avoid damage to motorcycle components or injury to persons. Moto Guzzi s.p.a. undertakes to
constantly improve the design of its products and the relevant literature to ensure that the customer is satisfied with the
product. The main technical modifications and changes in repair procedures are communicated to all Moto Guzzi
dealers and agencies worldwide. Such modifications will be included in subsequent editions of the manual. Should you
require assistance or clarifications regarding inspection and repair procedures, please contact the Moto Guzzi SERVICE
DEPT., which will be pleased to help, as well as providing you with updates and technical modifications regarding the
vehicle.
Moto Guzzi s.p.a. reserves the right to make changes to its products at any time, barring any such changes as may alter
the essential features of a product as specified in the relevant manual.
All rights of storage using electronic means, reproduction and total or partial adaptation, whatever the means adopted,
are reserved in all countries.
The mention of third parties’ products is only made for information purposes, and constitutes no engagement.
Moto Guzzi s.p.a. is not liable in any way for the performance or use of these products.
For further details, see REFERENCE MANUALS.
First edition: July 2005
Produced and printed by:
DECA s.r.l.
via Vincenzo Giardini, 11 - 48022 Lugo (RA) - Italy
Tel. +39 - 0545 216611
Fax +39 - 0545 216610
E-mail: deca@vftis.spx.com
www.vftis.com
On behalf of:
Moto Guzzi s.p.a.
via E.V. Parodi, 57- 23826 Mandello del Lario (Lecco) - Italy
Tel. +39 – 0341 - 709111
Fax +39 – 0341 - 709220
www.motoguzzi.it
www.servicemotoguzzi.com
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0.1.2. REFERENCE MANUALS
PARTS CATALOGUES
guzzi part# (description)
GU077_00
OWNER'S MANUALS
guzzi part# (description)
05.90.00.30
05.90.00.31
CHASSIS WORKSHOP MANUAL
aprilia part# (description)
8140856
8140857
8140858
8140859
8140860
8140861
8CM0077
8CM0078
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0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS
# = number
< = less than
> = greater than
≤ = less than or equal to
≥ = greater than or equal to
~ = approximately
∞ = infinity
°C = degrees Celsius (centigrade)
°F = degrees Fahrenheit
± = plus or minus
A.C. = alternating current
A = Ampere
Ah = Ampere per hour
API = American Petroleum Institute
AT = high voltage
AV/DC = Anti-Vibration Double Countershaft
bar = pressure measurement (1 bar = 100 kPa)
D.C. = direct current
cc = cubic centimeters
CO = carbon monoxide
CPU = Central Processing Unit
DIN = German industrial standards (Deutsche Industrie Norm)
DOHC = Double Overhead Camshaft
ECU = Electronic Control Unit
rpm = revolutions per minute
HC = unburnt hydrocarbons
ISC = Idle Speed Control
ISO = International Standardization Organization
kg = kilograms
kgm = kilogram meter (1 kgm = 10 Nm)
km = kilometers
km/h = kilometers per hour
kΩ = kilo Ohm
kPa = kiloPascal (1 kPa = 0.01 bar)
KS = clutch side (from the German "Kupplungsseite")
kW = kilowatt
l = liters
LAP = racetrack lap
LED = Light Emitting Diode
LEFT SIDE = left-hand side
m/s = meters per second
max = maximum
mbar = millibar (1 mbar = 0.1 kPa)
mi = miles
MIN = minimum
MPH = miles per hour
MS = flywheel side (from the German "Magnetoseite")
MΩ = MegaOhm
N.A. = Not Available
N.O.M.M. = Motor Octane Number
N.O.R.M. = Research Octane Number
Nm = Newton meter (1 Nm = 0.1 kgm)
Ω = ohm
PICK-UP = pick-up
BDC = Bottom Dead Centre
TDC = Top Dead Centre
PPC = Pneumatic Power Clutch
RIGHT SIDE = right-hand side
SAE = Society of Automotive Engineers
SAS = Secondary Air System
TEST = diagnostic check
T.B.E.I. = crown-head Allen screw
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T.C.E.I. = cheese-head Allen screw
T.E. = hexagonal head
T.P. = flat head screw
TSI = Twin Spark Ignition
UPSIDEDOWN = inverted fork
V = Volt
W = Watt
Ø = diameter
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GENERAL INFORMATION
GENERAL INFORMATION 1
1-1
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Breva V1100
TABLE OF CONTENTS
1.1.
STRUCTURE OF THE MANUAL...................................................................................................................... 3
1.1.1. CONVENTIONS USED IN THE MANUAL ................................................................................................. 3
1.1.2. SAFETY WARNINGS ................................................................................................................................ 4
1.2. GENERAL RULES............................................................................................................................................ 5
1.2.1. BASIC SAFETY RULES ............................................................................................................................ 5
1.3. DANGEROUS ELEMENTS............................................................................................................................... 8
1.3.1. WARNINGS ............................................................................................................................................... 8
1.4. RUNNING-IN .................................................................................................................................................. 11
1.4.1. RUNNING-IN ........................................................................................................................................... 11
1.5. POSITION OF THE SERIAL NUMBERS ........................................................................................................ 12
1.5.1. POSITION OF THE SERIAL NUMBERS................................................................................................. 12
1.6. USA VERSION ............................................................................................................................................... 13
1.6.1. POSITION OF THE ADHESIVE WARNING LABELS.............................................................................. 13
1.6.2. CALIFORNIA EVAPORATIVE EMISSION SYSTEM............................................................................... 17
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GENERAL INFORMATION
1.1. STRUCTURE OF THE MANUAL
1.1.1. CONVENTIONS USED IN THE MANUAL
• This manual is divided in sections and subsections, each covering a set of the most significant components. For
quick reference, see the summary of sections.
• Unless expressly specified otherwise, assemblies are reassembled by reversing the assembly procedure.
• The terms "left" and "right" are referred to the motorcycle when viewed from the riding position.
• Motorcycle operation and basic maintenance are covered in the "OWNER'S MANUAL".
In this manual any variants are identified with these symbols:
optional
catalytic version
- all versions
MP national certification
SF European certification (EURO 1 limits)
VERSION:
Italy
United
Kingdom
Austria
Portugal
Finland
Belgium
Germany
France
Spain
Greece
Holland
Switzerland
Denmark
Japan
Singapore
Slovenia
Israel
South Korea
Malaysia
Chile
Croatia
Australia
United States of America
Brazil
South Africa
New Zealand
Canada
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1.1.2. SAFETY WARNINGS
The symbols and warnings used throughout this manual have the following meanings:
Safety warning. When you find this symbol on the vehicle or in the manual, be careful of the potential
risk of personal injury. Disregarding the instructions identified by this symbol may compromise the
safety of the user, the motorcycle and third parties.
DANGER
Indicates a potential hazard which may result in serious injury or even death.
WARNING
Indicates a potential hazard which may result in minor personal injury or damage to the vehicle.
NOTE The word "NOTE" in this manual identifies important information or instructions.
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GENERAL INFORMATION
1.2. GENERAL RULES
1.2.1. BASIC SAFETY RULES
CARBON MONOXIDE
When an operation must be performed with the engine running, position the motorcycle outdoors in a well-ventilated
area.
Never run the engine in an enclosed place.
Use an exhaust emission extraction system when working indoors.
DANGER
Exhaust gases contain carbon monoxide, a poisonous gas which, if inhaled, may cause loss of
consciousness or even death.
FUEL
DANGER
The fuel used to operate engines is highly flammable and becomes explosive under particular
conditions.
Refueling and maintenance operations should be carried out in a well-ventilated area, with the engine
off.
Do not smoke when refueling or in the proximity of sources of fuel vapors. Avoid contact with bare
flames, sources of sparks and any other source which may ignite fuel or lead to explosion.
DO NOT DISPOSE OF FUEL IN THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
HOT COMPONENT PARTS
The engine and exhaust component parts become hot when the engine is running and will stay hot for some time after
the engine has been stopped.
Wear insulating gloves before handling these components or allow for the engine and the exhaust system to cool down
before proceeding.
USED GEARBOX AND FORK FLUIDS
DANGER
Wear latex gloves when servicing.
Prolonged or repeated contact with gear fluid may cause severe skin damage.
Wash your hands thoroughly after handling.
Dispose of it through the nearest waste oil reclamation firm or through the supplier.
Wear latex gloves when servicing.
DO NOT DISPOSE OF FLUID IN THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
BRAKE FLUID
WARNING
Brake fluid can damage plastic, rubber or painted parts. When servicing the brake system, protect all
such parts with a clean cloth.
Always wear safety glasses when servicing the brake system.
Brake fluid is highly irritant. Avoid contact with the eyes.
In case of contact with the eyes, rinse abundantly with cool, clean water and immediately seek
medical attention.
KEEP AWAY FROM CHILDREN.
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HYDROGEN GAS AND BATTERY ELECTROLYTE
DANGER
The battery electrolyte is a toxic, caustic substance containing sulfuric acid and thus able to cause
severe burns in case of contact.
Wear close-fitting gloves and protective clothing when handling this fluid.
If any battery fluid gets on your skin, rinse the affected area with abundant fresh water.
Take special care to protect the eyes; even a very small amount of battery fluid can cause blindness. If
battery fluid comes in contact with the eyes, flush with abundant water for fifteen minutes and contact
an eye specialist immediately.
If battery fluid is swallowed accidentally, drink abundant water or milk. Seek medical attention
immediately and keep drinking milk of magnesia or vegetable oil in the meantime.
The battery gives off explosive gases. Keep the battery well away from any sources of ignition, such
as flames, sparks, or any heat sources; do not smoke near the battery.
Make sure the area is well ventilated when servicing or refilling the battery.
KEEP AWAY FROM CHILDREN.
Battery fluid is corrosive.
Avoid spillage. Take special care not to spill battery fluid on plastic parts.
Make sure that the electrolyte fluid you are using is the suitable type for your battery.
GENERAL PRECAUTIONS AND INFORMATION
Follow these instructions closely when repairing, disassembling or reassembling the motorcycle or its components.
DANGER
Using bare flames is strictly forbidden when working on the motorcycle. Before servicing or
inspecting the motorcycle: stop the engine and remove the key from the ignition switch; allow for the
engine and exhaust system to cool down; where possible, lift the motorcycle using adequate
equipment placed on firm and level ground. Be careful of any parts of the engine or exhaust system
which may still be hot to the touch to avoid scalds or burns.
Never put mechanical parts or other vehicle components in your mouth when you have both hands
busy. None of the motorcycle components are edible. Some components are harmful to the human
body or toxic.
Unless expressly indicated otherwise, for the reassembly of the units repeat the disassembly
operations in reverse order. Where a procedure is cross-referred to relevant sections in the manual,
proceed sensibly to avoid disturbing any parts unless strictly necessary. Do not use polishing pastes
on matt paints.
Never use fuel instead of solvent to clean the motorcycle.
Do not clean rubber or plastic parts or the seat with alcohol, gasoline or solvents. Use only water and
mild soap.
Always disconnect the battery negative (-) lead before soldering any electrical components.
When two or more persons service the same motorcycle together, special care must be taken to avoid
personal injury.
For further warnings, see DANGEROUS ELEMENTS.
BEFORE REMOVING ANY COMPONENTS
• Clean off all dirt, mud, and dust and clear any foreign objects from the vehicle before disassembling any
components.
• Use the model-specific special tools where specified.
DISASSEMBLING THE COMPONENTS
- Never use pliers or similar tools to loosen and/or tighten nuts and bolts. Always use a suitable wrench.
- Mark the positions of all connections (hoses, wiring, etc.) before disconnecting them. Identify each connection using
a distinctive symbol or convention.
- Mark each part clearly to avoid confusion when refitting.
- Thoroughly clean and wash any components you have removed using a detergent with low flash point.
- Mated parts should always be refitted together. These parts will have seated themselves against one another during
running as a result of normal wear and tear and should never be mixed up with other similar parts when refitting.
- Certain components are matched-pair parts and should always be replaced as a set.
- Keep away from heat sources.
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GENERAL INFORMATION
REASSEMBLING THE COMPONENTS
DANGER
Never reuse a circlip or snap ring. These parts must always be replaced once they have been
removed.
When fitting a new circlip or snap ring, open the ends just enough to allow fitting to the shaft.
Make a rule to check that a newly fitted circlip or snap ring is fully housed in its groove.
Never use compressed air to clean bearings.
NOTE All bearings must run freely with no hardness or noise. Replace any bearings that do not meet these
requirements.
- Use ORIGINAL Moto Guzzi spare parts only.
- Use the specified lubricants and consumables.
- Where possible, lubricate a part before assembly.
- When tightening nuts and bolts, start with the largest or innermost nut/bolt and observe a cross pattern. Tighten
evenly, in subsequent steps, until the specified torque has been achieved.
- Replace any self-locking nuts, gaskets, seals, circlips or snap rings, O-rings, split pins, bolts and screws which have
a damaged thread.
- Lubricate the bearings abundantly before assembly.
- Make a rule to check that all components you have fitted are correctly in place.
- After repairing the motorcycle and after each service inspection, perform the preliminary checks, and then ride the
motorcycle in a private estate area or in a safe area away from traffic.
- Clean all mating surfaces, oil seal edges and gaskets before assembly. Apply a thin layer of lithium grease along the
edges of oil seals. Fit oil seals and bearings with the marking or serial number facing outwards (in view).
ELECTRICAL CONNECTORS
Disconnect electrical connectors as follows: failure to follow these instructions can seriously damage the connectors and
the wiring.
Press the special safety hooks, where fitted.
WARNING
• Grasp both connectors and pull them in two opposite directions until they become separated.
• Remove dirt, rust, moisture, etc., from inside the connectors with compressed air.
• Make sure that the wires are securely crimped to the terminals inside each connector.
NOTE A connector will fit properly only in the matching connector and when inserted in the correct fitting position.
• Reconnect the two connectors. Make sure they are correctly coupled (if fitted with hooks, it should click audibly into
TIGHTENING TORQUES
Never separate two connectors by pulling on the wiring.
place).
DANGER
Always remember that the tightening torques of all wheel, brake, wheel shaft and other suspension
parts are essential to ensuring safe operation of the motorcycle and must be set to the indicated
values. Make sure that these values are always within the specified limits.
Regularly check the tightening torques on all fastenings, and always use a torque wrench when fitting
them.
Failure to observe these instructions can result in parts loosening or coming away, thus jamming a
wheel or creating other problems which would affect the handling of the motorcycle, potentially
resulting in serious injury or death.
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1.3. DANGEROUS ELEMENTS
1.3.1. WARNINGS
FUEL
DANGER
The fuel used to operate engines is highly flammable and becomes explosive under particular
conditions.
Refueling and maintenance operations should be carried out in a well-ventilated area, with the engine
off.
Do not smoke when refueling or in the proximity of sources of fuel vapors. Avoid contact with bare
flames, sources of sparks or any other source which may ignite the fuel or lead to explosion.
Take care not to spill fuel out of the filler, as it may ignite when in contact with hot engine parts.
In the event of accidental fuel spillage, make sure the affected area is fully dry before starting the
engine. Fuel expands with heat and when left under direct sunlight.
Never fill the fuel tank up to the rim. Tighten the filler cap securely after each refueling.
Avoid contact with the skin and the inhalation of vapors; do not swallow fuel or pour it from a
receptacle into another by means of a tube.
DO NOT DISPOSE OF FUEL IN THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
Use only premium grade unleaded gasoline with a minimum octane rating of 95 RON and 85 MON.
LUBRICANTS
DANGER
Correct lubrication is essential to the safety of the motorcycle.
Failure to maintain the lubricant level or the use of incorrect, old or dirty lubricant can cause the
engine or transmission to seize, resulting in accident, serious injury or death.
Prolonged or repeated contact with gear fluid may cause severe skin damage.
Wash your hands thoroughly after handling.
Do not dispose oil in the environment.
For disposal, contact the nearest waste oil reclamation firm or the supplier.
WARNING
Avoid spillage when filling the vehicle with oil. Immediately clean up any spilt oil, which can damage
painted parts.
Oil on the tires can make them very slippery and dangerous to use.
In case of oil leaks, do not use the motorcycle. Identify the cause of the leak and repair it.
ENGINE OIL
DANGER
Prolonged or repeated contact with engine oil may cause severe skin damage.
Wash your hands thoroughly after handling.
Do not dispose oil in the environment.
For disposal, contact the nearest waste oil reclamation firm or the supplier.
Wear latex gloves when servicing.
FRONT FORK FLUID
DANGER
Front suspension response can be modified to a certain extent by changing damping settings and/or
selecting a particular grade of oil. Standard oil: SAE 20 W. Choose suitable viscosity grades according
to the desired set-up (choose SAE 5W for a softer suspension, 20W for a stiffer suspension).
The two grades can also be mixed in varying solutions to obtain the desired response.
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GENERAL INFORMATION
BRAKE FLUID
NOTE This vehicle is fitted with front and rear disc brakes. Each brake system is operated by an independent hydraulic
circuit. The information provided below applies to both brake systems.
DANGER
Do not drive the vehicle if the brakes are worn or not operating correctly. The brakes are the vehicle’s
most important safety component and using the vehicle with the brakes in less than perfect operating
condition comprises a high probability of traffic accident, which can result in serious injury or death.
The brakes are significantly less effective on a wet road surface.
DANGER
If the road surface is wet, maintain a double braking distance, as both the brakes and the grip of the
tires are significantly less effective in such conditions.
Water on brakes, whether due to a recent wash or picked up from a wet road surface, puddles or
drains, can result in significantly reduced brake efficiency.
Failure to observe these instructions can result in serious accidents, with the risk of serious personal
injury or death.
The brakes are essential to your safety. Do not drive the vehicle if the brakes on not in perfect
operating condition.
Always check the brakes before riding the motorcycle.
Brake fluid is an irritant. Avoid contact with eyes or skin.
In the event of accidental contact, wash affected body parts thoroughly. In the event of accidental
contact with the eyes, contact an eye specialist or seek medical attention.
DO NOT DISPOSE OF BRAKE FLUID IN THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
Avoid spillage. Brake fluid can damage plastic or painted parts.
DANGER
Do not use brake fluids other than the specified type. Never mix different types of fluids to top up the
level, as this will damage the brake system.
Do not use brake fluid from containers which have been kept open or in storage for long periods of
time.
Any sudden changes in slack or hardness in the brake levers are warning signs of problems with the
hydraulic circuits.
Make sure that the brake discs and brake linings have not come in contact with oil or grease. This is
particularly important after servicing or inspections.
Make sure the brake lines are not twisted or worn.
Avoid accidental entry of water or dust into the circuit.
Wear latex gloves when servicing the hydraulic circuit.
DISC BRAKES
DANGER
The brakes are the vehicle’s most important safety component.
To ensure your personal safety, they must be in perfect working order and should be checked before
every ride.
Dirty pads must be replaced. Dirty or oily discs must be cleaned with a high-quality degreasing
product.
If the vehicle is often used on wet road surfaces or on dusty or rough tracks, or in case of use in
competition, reduce the service intervals by half.
Check brake pads for wear.
When the brake pads are worn, the fluid level lowers to compensate for the wear.
The front brake fluid reservoir is on the RH side of the handlebar, next to the front brake lever.
The rear brake fluid reservoir is located under the RH side fairing.
Do not use the vehicle if the brake system leaks fluid.
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TIRES
WARNING
An over inflated tire results in a hard, uncomfortable and less secure ride.
Over inflation also affects grip, especially on curves and wet surfaces.
An under inflated tire (insufficient pressure) can slip on the wheel rim, resulting in loss of control.
Under inflation also affects grip and handling, as well as braking efficiency.
Tire replacement and repair, and wheel servicing and balancing are delicate operations. They should
be carried out using adequate tools and are best left to experienced mechanics.
New tires may be covered with a thin layer of protective coating which is slippery. Drive carefully for
the first few kilometers (miles).
Never use any kind of rubber treatment product on the tires.
In particular, do not allow the tire to come in contact with liquid fuel, which rapidly deteriorates the tire
rubber.
In case of contact with oil or fuel, do not clean but replace the tire.
DANGER
Some of the factory-assembled tires on this vehicle are equipped with wear indicators.
There are various types of wear indicators.
For more information on how to check wear, contact your Dealer.
Check the wear visually and have the tires replaced when they are worn.
If a tire deflates during a ride, do not attempt to continue the trip.
Avoid sudden braking or steering maneuvers, and do not decelerate rapidly.
Slowly decelerate and move to the edge of the road braking with the engine until you come to a
standstill.
Failure to observe these instructions can result in serious accidents, with the risk of serious personal
injury or death.
Never use tube tires on tubeless tire rims, or vice versa.
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GENERAL INFORMATION
1.4. RUNNING-IN
1.4.1. RUNNING-IN
Proper engine running in is essential to preserving engine life and performance over time.
Twisty roads and gradients are ideal to break in engine, suspension and brakes effectively.
Varying speed frequently is also recommended.
This will vary the amount of stress placed on vehicle components continuously, allowing engine parts to cool down when
less stressed.
While it is important to put a certain amount of stress to engine components during the running-in period, it is equally
important to spare the engine at this stage in the vehicle’s life.
WARNING
Top acceleration performance is only obtained after covering the first 2000 km (1243 mi).
Follow these recommendations:
• Do not open the throttle completely when the engine is running at low speed, both during and after the running-in
period.
• Until you have covered the first 100 km (62 mi), use the brakes gently and avoid harsh, prolonged braking. This will
help the brake pads bed in properly against the brake disc.
• During the first 1000 km (621 mi), never exceed 5000 rpm (see table).
WARNING
After covering the first 1000 km (621 mi), perform the checks listed in the "After running-in" column,
see REGULAR SERVICE INTERVALS CHART to avoid personal injury to yourself or third persons, or
vehicle damage.
• After the first 1000 km (621 mi) and until covering 2000 km (1243 mi), drive more briskly, varying speed and using
maximum acceleration for just a few seconds, in order to ensure better component coupling; never exceed 6000
rpm (see table).
• After the first 2000 km (1243 mi) you may run the engine harder, however, without exceeding the maximum rpm
allowed (7600 rpm).
Recommended maximum rpm
Mileage km (mi) rpm
0-1000 (621) 5000
1000-2000 (621-1243) 6000
Over 2000 (1243) 7600
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1.5. POSITION OF THE SERIAL NUMBERS
1.5.1. POSITION OF THE SERIAL NUMBERS
These numbers are necessary for vehicle registration.
IMPORTANT: Altering the vehicle's identification numbers is
punishable by law with heavy fines and penalties. Altering
the frame number voids the warranty.
FRAME NUMBER
The frame number (Vehicle Identification Number) is
stamped on the right-hand side of the headstock.
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ENGINE NUMBER
The engine number is stamped on the right-hand side of the
engine next to the oil level plug.
DIGIT MEANING
1. Manufacturer’s identification alphanumeric code
2. Vehicle type
3. Model
4. Country for which the vehicle is intended
5. # = Check digit number
6. Model year
7. Designation of assembling factory (M = Mandello)
8. Sequential serial number
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1.6. USA VERSION
1.6.1. POSITION OF THE ADHESIVE WARNING LABELS
GENERAL INFORMATION
1
2
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GENERAL INFORMATION
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GENERAL INFORMATION
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11
Breva V1100
12 Muffler stamping.
1 - 16
Breva V1100
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1.6.2. CALIFORNIA EVAPORATIVE EMISSION SYSTEM
GENERAL INFORMATION
The system consists of:
1. Fuel tank
2. Fuel tank breather line
3. Breather line
4. 1-way ventilation valve
5. Breather line (to carbon canister)
6. Carbon canister
7. Drain line
8. Fitting
9. Breather line
10. Tee
11. Drain line
12. Fresh air line
1-17
Breva V1100
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PERIODIC MAINTENANCE
PERIODIC MAINTENANCE 2
2-1
PERIODIC MAINTENANCE
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Breva V1100
TABLE OF CONTENTS
2.1.
TECHNICAL INFORMATION............................................................................................................................ 3
2.1.1. TECHNICAL DATA.................................................................................................................................... 3
2.1.2. SCHEDULED MAINTENANCE CHART .................................................................................................... 5
2.1.3. LUBRICANT TABLE .................................................................................................................................. 7
2.1.4. TIGHTENING TORQUE SETTINGS ......................................................................................................... 8
2.1.5. SPECIAL TOOLS .................................................................................................................................... 12
2.1.6. ARRANGEMENT OF THE MAIN ELEMENTS......................................................................................... 13
2.1.7. LOCATION OF INSTRUMENTS/CONTROLS......................................................................................... 15
2.2. MAINTENANCE OPERATIONS ..................................................................................................................... 17
2.2.1. CHANGING ENGINE OIL AND OIL FILTER ........................................................................................... 17
2.2.2. GEARBOX OIL ........................................................................................................................................ 19
2.2.3. GEARBOX FLUID.................................................................................................................................... 20
2.2.4. CLEANING THE AIR FILTER .................................................................................................................. 21
2.2.5. ADJUSTING THE VALVE CLEARANCE ................................................................................................. 22
2.2.6. FRONT BRAKE ....................................................................................................................................... 23
2.2.7. REAR BRAKE.......................................................................................................................................... 25
2 - 2
Breva V1100
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PERIODIC MAINTENANCE
2.1. TECHNICAL INFORMATION
2.1.1. TECHNICAL DATA
DIMENSIONS
Length 2195 mm (86.4 in.)
Width 870 mm (34.2 in.)
Maximum height 1125 mm (44.3 in.)
Seat height 800 mm (31.5 in.)
Minimum ground clearance 185 mm (7.3 in.)
Wheelbase 1495 mm (58.8 in.)
Weight in running order 248 kg (547 lb)
ENGINE
Type twin-cylinder, 90° V transversal, 4-stroke engine
Number of cylinders two
Cylinder arrangement V, 90°
Total displacement 1064 cm3 (65 in3)
Bore/stroke 92 x 80 mm (3.6 x 3.1 in).
Compression ratio 9.6 : 1
Starting electric
Engine idling speed 1100 ± 100 rpm
Clutch single plate, dry clutch with cush drive damper
Lubricating system System under pressure, adjustment by valves and vane pump
Air filter cartridge, dry
Cooling system air cooled
CAPACITIES
Fuel (including reserve) 23 liters (6.1 gal)
Fuel reserve 4 liters (1.06 gal)
Engine oil Engine oil and oil filter change 3900 cm3 (238 in3)
Gearbox fluid 500 cm3 (30.5 in3)
Transmission fluid 380 cm3 (23.2 in3)
Front fork fluid 400 ± 2.5 cm3 (24.4 ± 0.15 in3) (per leg)
Seat 2
Vehicle maximum load 230 kg (507 lb) (rider + passenger + luggage)
TIMING SYSTEM
Timing diagram: 2 valves, with rods and rocker arms
Values with inspection clearance between
rocker arms and valve
TRANSMISSION SYSTEM
- Primary drive gear, ratio: 26/35 = 1:1.3461
- Gearbox Mechanic, with 6 speeds, controlled by a pedal on engine left side
- Overall gear ratios:
1st gear 17/38 = 1:2.2353
2nd gear 20/34 = 1:1.7
3rd gear 23/31 = 1:1.3478
4th gear 26/29 = 1:1.1154
5th gear 31/30 = 1:0.9677
- Final drive with cardan joint
- Ratio 12/44 = 1:3.6667
FUEL SYSTEM
Type Electronic injection (Weber – Marelli) with stepper motor
Choke Ø 36 mm (1.417 in.)
Fuel Premium grade unleaded fuel, minimum octane rating 95 (RON) and
FRAME
Type with double split cradle in steel tubes with high yield point
Trail 120 mm (4.72 in.)
Rake 25° 30’
intake 0.10 mm (0.0039 in.)
exhaust 0.15 mm (0.0059 in.)
85 (MON).
2-3
PERIODIC MAINTENANCE
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SUSPENSIONS
Front hydraulic telescopic fork Ø 45 mm (1.77 in).
Front travel 120 mm (4.72 in.)
Rear single-sided with progressive leverage, monoshock adjustable in
Wheel travel 110 mm (4.33 in.)
BRAKES
Front twin floating disc in stainless steel Ø 320 mm (12.6 in), caliper with 4
Rear Stainless steel disc Ø 282 mm (11.1 in)
WHEELS
Type with 3 hollow spokes chill-cast in aluminum alloy
Front wheel rim 3.50" x 17"
Rear wheel rim 5.50" x 17"
TIRES
Type BRIDGESTONE BATLAX or, as an alternative, IRELLI SPORT
- front size: 120/70 – ZR 17” 58 W
inflating pressure: 250 Kpa (36.3 PSI)
inflating pressure with passenger: 250 Kpa (36.3 PSI)
- rear size: 180/55 – ZR 17” 73 W
inflating pressure: 280 Kpa (40.6 PSI)
inflating pressure with passenger: 280 Kpa (40.6 PSI)
SPARK PLUGS
Internal (long life) NGK PMR8B
External NGK BPR6ES
Electrode gap 0.6 – 0.7 mm (0.024 – 0.028 in.)
ELECTRIC SYSTEM
Battery 12 V – 18 Ampere/hour
Generator (with permanent magnet) 12 V – 550 W
Main fuses 30 A
Auxiliary fuses 3 A – 15 A – 20 A
BULBS
Parking light 12 V – 5 W
Low beam 12 V - 55 W - H7
High beam 12 V - 65 W - H9
Turn indicators 12V – 10 W (orange lamp)
Rear parking lights/stoplights LED
Instrument lights LED
License plate light 12 V – 5 W
WARNING LIGHTS
Turn indicators LED
ABS LED
Gear in neutral LED
Alarm LED
Side stand down LED
Fuel reserve LED
High beam LED
Antitheft LED
Gear shift indicator LED
rebound and with ergonomic knob for spring preload adjustment.
separated opposed pistons
DAEMON
Breva V1100
2 - 4
Breva V1100
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PERIODIC MAINTENANCE
2.1.2. SCHEDULED MAINTENANCE CHART
OPERATIONS TO BE CARRIED OUT BY THE Moto Guzzi Authorized dealer (CAN BE CARRIED OUT BY THE USER
AS WELL).
1 = check and clean, adjust, lubricate or change, if necessary;
2 = clean;
3 = replace;
4 = adjust.
NOTE Carry out the maintenance operations more frequently if you use the vehicle in rainy and dusty areas, on uneven
ground, or for racing.
(*) = Change every 5000 Km (3125 mi), if used for racing
(**) = Check every two weeks or at indicated intervals.
Component
External plugs (*) - 3 Engine oil filter (*) 3 3 Fork 1 - 1
Headlight beam direction - operation - 1 Light system 1 1 Safety switches 1 1 Brake fluid - 1 Engine oil 3 3 Tires 1 1 Tire pressure (**) 4 4 Idling rpm 4 4 Battery terminal tightening 1 - Head bolt tightening 4 - Engine oil pressure warning light at every starting: 1
Brake pad wear
Emptying the oil drain hose from filter box end Every 5000 km (3125 mi):2
After running-in
[1000 km (621 mi)]
1
Every 10000 km
(6250 mi) or 12
months
before every trip and
every 2000 Km (1250 mi): 1
Every 20000 km
(12500 mi) or 24
months
2-5
PERIODIC MAINTENANCE
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OPERATIONS TO BE CARRIED OUT BY THE Moto Guzzi Authorized dealer.
1 = check and clean, adjust, lubricate or change, if necessary;
2 = clean;
3 = replace;
4 = adjust.
NOTE Carry out the maintenance operations more frequently if you use the vehicle in rainy and dusty areas, on uneven
ground, or for racing.
(*) = Change every 5000 Km (3125 mi), if used for racing
(**) = Check every two weeks or at indicated intervals.
Component
Gearbox fluid 3 3 Idle mixture (CO) - 1 Transmission and control cables 1 1 Steering bearings and steering play 1 1 Wheel bearings - 1 Brake discs 1 1 Air filter - 1 3
Vehicle general operation 1 1 Brake systems 1 1 Brake fluid - - 3
Front fork fluid after the first 10000 km (6250 mi)
Fork oil seals after the first 30000 km (18750 mi)
Brake pads every 2000 Km (1250 mi): 1 - if worn: 3
Adjusting valve clearance 4 4 Wheels / Tires 1 1 Tightening nuts and bolts 1 1 Tightening battery terminals 1 - Cylinder synchronization 1 1 Suspensions and trim 1 - 1
Final transmission fluid 3 3 Fuel hoses - 1 Every four years: 3
Brake lines - 1 Every four years: 3
Clutch wear (*) - 1 Internal spark plugs - - 4
Generator belt every 20000 Km (12500 mi): 4, every 50000 Km (31250 mi): 3
Tightening head stud bolts 4 - Exhaust pipe flange bolts 1 - -
After running-in
[1000 km (621 mi)]
and then every 20000 km (12500 mi)3.
and then every 20000 km (12500 mi): 3.
Every 10000 km
(6250 mi) or 12
months
Every 20000 km
(12500 mi) or 24
Breva V1100
months
2 - 6
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