MOTO GUZZI Nevada Classic 750 ie 2004 Workshop Manual
00/2004-05
Nevada Classic 750 ie
UK
UK
Cod. 32 92 01 64
Cod. 32 92 01 64
workshopmanual
NEVADA 750 i.e.
INTRODUCTION
INTRODUCTION 0
0 - 1
INTRODUCTION
NEVADA 750 i.e.
SUMMARY
0.1. INTRODUCTION .............................................................................................................................................. 3
0.1.1. INTRODUCTION ....................................................................................................................................... 3
0.1.2. REFERENCE MANUALS .......................................................................................................................... 4
0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS ........................................................................................ 5
0 - 2
NEVADA 750 i.e.
INTRODUCTION
0.1. INTRODUCTION
0.1.1. INTRODUCTION
- This manual provides the information required for normal servicing.
- This publication is intended for use by Moto Guzzi dealerships and their qualified mechanics; many concepts have
been omitted inasmuch as their inclusion would be superfluous for such an audience. Since complete mechanical
explanations have not been included in this manual, the reader must be familiar with basic notions of mechanics, as
well as with basic repair procedures. Without such familiarity, repairs and checks could be ineffective and even
hazardous. Since the repair and vehicle check instructions are not exhaustive, special care must be taken to avoid
damage and injury. To ensure maximum customer satisfaction with the vehicle, Moto Guzzi spa continuously
improves its products and their documentation. The main technical modifications and changes in repair procedures
are communicated to all Moto Guzzi dealerships and agencies worldwide. Such modifications will be entered in
subsequent editions of the manual. In case of doubt regarding specific repairs or checks, contact the Moto Guzzi
SERVICE DEPARTMENT; we will be pleased to provide all necessary information and assistance as well as
keeping you updated on changes and modifications to 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 spa is not liable in any way for the performance or use of its products.
For more details see (REFERENCE MANUALS)
First edition: May 2004
Designed and printed by:
DECA s.r.l.
via Risorgimento, 23/1 - 48022 Lugo (RA) - Italy
Tel. +39 - 0545 35235
Fax +39 - 0545 32844
E-mail: deca@decaweb.it
www.decaweb.it
On behalf of:
Moto Guzzi s.p.a.
via E.V. Parodi, 57- 23826 Mandello del Lario (Lecco) - Italy
Tel. +39 – (0)341 - 709111
Fax +39 – (0)341 - 709220
www.motoguzzi.it
www.servicemotoguzzi.com
0 - 3
INTRODUCTION
0.1.2. REFERENCE MANUALS
PARTS CATALOGUES
guzzi part# (description)
GU07500
OWNER’S MANUALS
guzzi part# (description)
32.90.00.60
32.90.00.61
32.90.00.62
CYCLE PARTS TECHNICAL MANUAL
guzzi part# (description)
32.92.01.60
32.92.01.61
32.92.01.62
32.92.01.63
32.92.01.64
32.92.01.65
ENGINE TECHNICAL MANUAL
guzzi part# (description)
32.92.02.10
32.92.02.11
32.92.02.12
32.92.02.13
32.92.02.14
32.92.02.15
NEVADA 750 i.e.
0 - 4
NEVADA 750 i.e.
0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS
# = number
< = less than
> = greater than
≤ = less than or equal to
≥ = more than or equal to
~ = approximately
∞ = infinity
°C = degrees Celsius (centigrade)
°F = degrees Fahrenheit
± = plus or minus
AC = alternating current
A = Ampere
Ah = Ampere per hour
API = American Petroleum Institute
HV = high voltage
AV/DC = Anti-Vibration Double Countershaft
bar = pressure measurement (1 bar =100 kPa)
DC. = Direct Current
cc = cubic centimetres
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 metre (1 kgm =10 Nm)
km = kilometres
kph = kilometres per hour
Ω = kilo Ohm
k
kPa = kiloPascal (1 kPa =0.01 bar)
KS = clutch side (from the German "Kupplungseite")
kW = kiloWatt
l = litres
LAP = racetrack lap
LED = Light Emitting Diode
LEFT SIDE = left side
m/s = metres 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")
M
Ω = megaOhm
N.A. = Not Available
N.O.M.M. = Motor Octane Number
N.O.R.M. = Research Octane Number
Nm = Newton metre (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 side
SAE = Society of Automotive Engineers
TEST = diagnostic check
T.B.E.I. = crown-head Allen screw
INTRODUCTION
0 - 5
INTRODUCTION
T.C.E.I. = cheese-head Allen screw
T.E. = hexagonal head
TP = flat head screw
TSI = Twin Spark Ignition
UPSIDEDOWN = inverted fork
V = Volt
W = Watt
Ø = Diameter
NEVADA 750 i.e.
0 - 6
NEVADA 750 i.e.
GENERAL INFORMATION
GENERAL INFORMATION 1
1-1
GENERAL INFORMATION
NEVADA 750 i.e.
SUMMARY
0.1. STRUCTURE OF THE MANUAL..................................................................................................................... 3
0.1.1. CONVENTIONS USED IN THE MANUAL ............................................................................................. 3
0.1.2. SAFETY WARNINGS............................................................................................................................. 4
0.2. GENERAL RULES........................................................................................................................................... 5
0.2.1. BASIC SAFETY RULES......................................................................................................................... 5
0.3. DANGEROUS ELEMENTS ............................................................................................................................. 9
0.3.1. WARNINGS ........................................................................................................................................... 9
0.4. RUNNING-IN ................................................................................................................................................. 12
0.4.1. RUNNING-IN RECOMMENDATIONS.................................................................................................. 12
0.5. LOCATION OF SERIAL NUMBERS.............................................................................................................. 13
0.5.1. LOCATION OF SERIAL NUMBERS .................................................................................................... 13
1 - 2
NEVADA 750 i.e.
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. Refer
to the index of sections when consulting the manual.
• Unless expressly specified otherwise, assemblies are reassembled by reversing the dismantling procedure.
• The terms "right" and "left" are referred to the rider seated on the vehicle in the normal 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
1-3
GENERAL INFORMATION
1.1.2. SAFETY WARNINGS
The following precautionary warnings are used throughout this manual in order to convey the following messages:
Safety warning. This symbol appears, whether in the manual or on the vehicle itself, to indicate a
personal injury hazard. Non-compliance with the indications given in the messages preceded by this
symbol may result in grave risks for your and other people's safety and for the vehicle!
WARNING
Indicates a potential hazard which may result in serious injury or even death.
CAUTION
Indicates a potential hazard which may result in minor personal injury or damage to the vehicle.
IMPORTANT: The word "IMPORTANT" in this manual precedes important information or instructions.
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NEVADA 750 i.e.
GENERAL INFORMATION
1.2. GENERAL RULES
1.2.1. BASIC SAFETY RULES
CARBON MONOXIDE
Should it be necessary to perform some operations with the vehicle running, make sure to work outdoors or in a wellaerated room.
Avoid starting the engine in closed or badly-ventilated rooms.
In case you are working indoors, make use of an exhaust gases scavenging system.
DANGER
Exhaust gases contain carbon monoxide, which is extremely toxic if inhaled and may cause loss of
consciousness or even lead to death by asphyxia.
FUEL
DANGER
The fuel used to operate engines is highly flammable and becomes explosive under particular conditions.
Refuelling and engine service should take place in a well-ventilated area with the engine stopped. Do not
smoke when refuelling or in the proximity of sources of fuel vapours, avoid flames, sparks and any
element that could ignite fuel or provoke explosions.
DO NOT DISPOSE OF FUEL IN THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
HIGH-TEMPERATURE COMPONENTS
The engine and the exhaust system parts become hot and continue to be hot even for some time after the engine has
been stopped.
Before handling these parts, wear insulating gloves or wait for the engine and the exhaust system to cool completely
down.
USED GEARBOX AND FORK OILS
DANGER
In case any maintenance operation should be required, it is advisable to use latex gloves.
Gear oil may cause serious damage to the skin if handled daily and for long periods.
Wash your hands carefully after use.
Put it in a sealed container and take it to the filling station where you usually buy it or to an oil salvage
center.
In case any maintenance operation should be required, it is advisable to use latex gloves.
DO NOT DISPOSE OF OIL IN THE ENVIRONMENT
KEEP AWAY FROM CHILDREN.
BRAKE FLUID
WARNING
When using the brake fluid, take care not to spill it on the plastic, rubber or painted parts, since it can
damage them.
When carrying out the maintenance operations on the braking system, use a clean cloth to cover these
parts.
Always wear safety goggles when working on the braking system.
The brake fluid is highly irritant. Avoid contact with your eyes.
If the brake fluid gets in contact with the skin or the eyes, carefully wash the parts of your body that get
in contact with the fluid and consult a doctor.
KEEP AWAY FROM CHILDREN.
1-5
GENERAL INFORMATION
HYDROGEN GAS AND BATTERY ELECTROLYTE
DANGER
The battery electrolyte is a toxic, caustic substance containing sulphuric acid and thus able to cause
severe burns in case of contact.
Always wear tight gloves and protective clothes when handling this fluid.
If the electrolyte gets in contact with the skin, carefully wash the parts of your body that get in contact
with the fluid with abundant fresh water.
Always use a protection for your eyes since also a very small amount of the battery fluid can cause
blindness. In the event of contact with your eyes, carefully wash them with water for fifteen minutes and
then consult immediately an eye specialist.
Should you accidentally drink some fluid, drink abundant water or milk, then drink magnesia milk or
vegetable oil and consult immediately a doctor. Battery releases explosive gases. Keep flames, sparks,
cigarettes and any other heat source away from the battery. Make sure the room is well-aerated when
servicing or recharging the battery.
KEEP AWAY FROM CHILDREN.
The battery fluid is corrosive
Do not pour it on the plastic parts.
Make sure that the electrolyte acid is suitable for the type of battery used.
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 any mechanical parts or other vehicle components in your mouth when you have both hands
busy. None of the motorcycle components is edible. Some components are harmful to the human body
or toxic.
Unless expressly specified otherwise, motorcycle assemblies are refitted or re-assembled by reversing
the removal or dismantling procedure. Where a procedure is cross-referred to relevant sections in the
manual, proceed sensibly to avoid disturbing any parts unless strictly necessary. Never attempt to polish
matte-finished surfaces with lapping compounds.
Never use fuel instead of solvent to clean the motorcycle.
Do not clean any rubber or plastic parts or the seat with alcohol, petrol or solvents. Clean with water and
neutral detergent.
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.
Read (DANGEROUS ELEMENTS).
NEVADA 750 i.e.
1 - 6
NEVADA 750 i.e.
GENERAL INFORMATION
BEFORE DISASSEMBLING 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 slacken and/or tighten nuts and bolts. Always use a suitable spanner.
- Mark all connections (hoses, wiring, etc.) with their positions 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 in
service as a result of normal wear and tear and should never be mixed up with other similar parts on refitting.
- Certain components are matched-pair parts and should always be replaced as a set.
- Keep the motorcycle and its components well away from heat sources.
REASSEMBLING THE COMPONENTS
DANGER
Never reuse a circlip or snap ring. These parts must always be renewed once they have been disturbed.
When fitting a new circlip or snap ring, take care to move the open ends apart just enough to allow
fitment to the shaft.
Make a rule to check that a newly –fitted circlip or snap ring has located fully into its groove.
Never clean a bearing with compressed air.
NOTE All bearings must rotate 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 achieving the specified torque.
- 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 operate
the motorcycle in a private estate area or in a safe area away from traffic.
- Clean all joint surfaces, oil seal edges and gaskets before assembly. Apply a light coat 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
To disconnect the electrical connector, follow the procedures below. Failure to comply with these procedures may lead to
irreparable damages to the connector and the wiring as well. If present, press the special safety hooks.
WARNING
Do not pull cables to disconnect the two connectors.
• Grasp the two connectors and disconnect them by pulling them in the two opposite directions.
• In case of dirt, rust, moisture, etc.., thoroughly clean the inside of the connectors with compressed air.
• Make sure that the cables are correctly fitted inside the connectors terminals.
NOTE The two connectors have just one correct positioning. Make sure to position them in the right direction.
• Then fit the two connectors. Make sure they are correctly coupled (a click will be heard).
TIGHTENING TORQUE SETTINGS
DANGER
Always remember that the tightening torque settings of all wheel, brake, wheel shaft and other
suspension parts play a fundamental role to ensure vehicle safety. Make sure that these values are
always within the specified limits.
Check fastening parts tightening torque settings at regular intervals. Upon reassembly, always use a
torque wrench.
Failure to comply with these recommendations could lead to the loosening and detachment of one of
these parts with a consequent locking of the wheel or other serious troubles affecting the vehicle
maneuverability, and thus the risk of falls and serious injuries or death.
1-7
GENERAL INFORMATION
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.
Refuelling and engine service should take place in a well-ventilated area with the engine stopped. Do not
smoke when refuelling or in the proximity of sources of fuel vapours. 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, or 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 from heat and when left under direct sunlight.
Never fill the fuel tank up to the rim. Tighten the filler cap securely after each refuelling.
Avoid contact with skin. Do not inhale vapours. Do not swallow fuel. Do not transfer fuel between
different containers using a hose.
DO NOT RELEASE FUEL INTO THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
Use only premium grade unleaded petrol, min. O.N. 95 (N.O.R.M.) and 85 (N.O.M.M.).
LUBRICANTS
DANGER
A good lubrication ensures the vehicle safety.
Failure to keep the lubricants at the recommended level or the use of a non-suitable new and clean type
of lubricant can lead to the engine or gearbox seizure, thus leading to serious accidents, personal injury
or even death.
Gear oil may cause serious damage to the skin if handled daily and for long periods.
Wash your hands carefully after use.
Do not dispose of oil into the environment.
Take it to the filling station where you usually buy it or to an oil salvage center.
WARNING
When filling the vehicle with this oil, take care not to spill it out since it could damage the vehicle
paintwork.
In case of contact with oil, the tyres surface will become very slippery, thus becoming a serious danger
for your safety.
In case of leaks, do not use the vehicle. Check and trace the cause of leaks and proceed to repair.
ENGINE OIL
DANGER
Prolonged or repeated contact with engine oil may cause severe skin damage.
Wash your hands thoroughly after handling engine oil.
Do not release into the environment.
Dispose of engine oil through the nearest waste oil reclamation firm or through the supplier.
Wear latex gloves during 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 grade is SAE 20 W. Different oil grades can be selected to
obtain a particular suspension response. (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.
NEVADA 750 i.e.
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NEVADA 750 i.e.
GENERAL INFORMATION
BRAKE FLUID
NOTE This vehicle is fitted with front and rear disc brakes. Each braking system is operated by an independent hydraulic
circuit. The information provided below applies to both braking systems.
DANGER
Do not use the vehicle in case brakes are worn out or do not work properly! The brakes are the parts that
most ensure your safety and for this reason they must always be perfectly working. Failure to comply
with these recommendations will probably lead to a crash or an accident, with a consequent risk of
personal injury or death.
A wet surface reduces brakes efficiency.
DANGER
In case of wet ground the braking distance will be doubled, since both brakes and tyres drives on the
road surface are extremely reduced by the water present on the road surface.
Any water on brakes, after washing the vehicle or driving on a wet road surface or crossing puddles or
gips, can wet brakes so as to greatly reduce their efficiency.
Failure to comply with these recommendations may lead to serious accidents, with a consequent risk of
severe personal injuries or death.
Brakes are critical safety components. Do not ride the vehicle in case brakes are not working at their
best.
Check for brakes proper operation before every trip.
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 eyes, contact an eye specialist or seek medical advice.
DO NOT RELEASE BRAKE FLUID INTO THE ENVIRONMENT.KEEP AWAY FROM CHILDREN.
When handling brake fluid, take care not to spill it onto plastic or paint-finished parts or they will damage.
DANGER
Do not use any brake fluids other than the specified type. Never mix different types of fluids to top up
level, as this will damage the braking system.
Do not use brake fluid from containers which have been kept open or in storage for long periods.
Any sudden changes in play or hardness in the brake levers are warning signs of problems with the
hydraulic circuits.
Ensure that the brake discs and brake linings have not become contaminated with oil or grease. This is
particularly important after servicing or inspections.
Make sure the brake lines are not twisted or worn.
Prevent accidental ingress of water or dust into the circuit.
Wear latex gloves when servicing the hydraulic circuit.
DISC BRAKES
DANGER
The brakes are the parts that most ensure your safety and for this reason they must always be perfectly
working; check them before every trip.
A dirty disc soils the pads.
Dirty pads must be replaced, while dirty discs must be cleaned with a high-quality degreaser.
Perform the maintenance operations with half the indicated frequency if the vehicle is used in rainy or
dusty areas, on uneven surfaces or on racetracks.
When the disc pads wear out, the level of the fluid decreases to automatically compensate for their wear.
The front brake fluid reservoir is located on the right handlebar, near the front brake lever.
The rear brake fluid reservoir is located under the right fairing.
Do not use the vehicle if the braking system leaks fluid.
1-9
GENERAL INFORMATION
COOLANT
DANGER
Coolant is toxic when ingested and is an irritant, contact with eyes or skin may cause irritation.
In the event of contact with eyes, rinse repeatedly with abundant water and seek medical advice. In the
event of ingestion, induce vomiting, rinse mouth and throat with abundant water and seek medical advice
immediately.
DO NOT RELEASE INTO THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
DANGER
Take care not to spill coolant onto hot engine parts. It may ignite and produce invisible flames. Wear
latex gloves when servicing.
Do not ride when coolant is below the minimum level.
Coolant mixture is a 50% solution of water and anti-freeze. This is the ideal solution for most operating temperatures and
provides good corrosion protection.
This solution is also suited to the warm season, as it is less prone to evaporative loss and will reduce the need for topups.
In addition, less water evaporation means fewer minerals salts depositing in the radiator, which helps preserve the
efficiency of the cooling system.
When temperature drops below zero degrees centigrade, check the cooling system frequently and add more anti-freeze
(up to 60% maximum) to the solution.
Use distilled water in the coolant mixture. Tap water will damage the engine.
Refer to the chart given below and add water with the quantity of anti-freeze to obtain a solution with the desired freezing
point:
Freezing point °C (-F°) Coolant % of volume
-20° (-4) 35
-30° (-22) 45
-40° (-40) 55
NOTE Coolants have different specifications. The protection degree is written on the label.
WARNING
Use nitrate-free coolant only, with a protection until at least -35°C (-31°F).
NEVADA 750 i.e.
1 - 10
NEVADA 750 i.e.
TYRES
WARNING
If tyres are excessively inflated, the vehicle will be hard and uneasy to ride, thus making you feel not at
your ease.
In addition the roadworthiness, mainly on wet surfaces and during cornering, will be impaired.
Flat tyres (insufficient pressure) can slip on the rim and make you lose the control of the vehicle.
In this case too, both vehicle roadworthiness, maneuverability and brake efficiency will be impaired.
Tyres changing, repair, maintenance and balancing must be carried out by specialized technicians using
suitable equipment.
When new, tyres can have a thin slippery protective coating. Drive carefully for the first kilometers
(miles). Never use rubber treating substances on tyres.
In particular, avoid contact with fluid fuels, leading to a rapid wear.
In case of contact with oil or fuel, do not clean but change tyres.
DANGER
Some of the factory-assembled tyres of this vehicle are provided with wear indicators.
There are several kinds of wear indicators.
For more information on how to check the wear, contact your Dealer.
Visually check if the tyres are worn and in this case have them changed.
If a tyre deflates while driving, stop immediately.
Avoid hard brakings or moves and do not close throttles too abruptly.
Slowly close throttle grip, move to the edge of the road and make use of the engine brake to slow down
until coming to a halt.
Failure to comply with these recommendations can lead to serious accidents and consequent personal
injuries or death.
Do not install tyres with air tube on rims for tubeless tyres and viceversa.
GENERAL INFORMATION
1-11
GENERAL INFORMATION
NEVADA 750 i.e.
1.4. RUNNING-IN
1.4.1. RUNNING-IN RECOMMENDATIONS
The running-in of the engine is essential to ensure its duration and correct functioning.
If possible, drive on hilly roads and/or roads with many bends, so that the engine, the suspensions and the brakes
undergo a more effective running-in.
During running-in, change speed.
In this way the components are first "loaded" and then "relieved" and the engine parts can thus cool down.
Even if it is important to stress the engine components during running-in, take care not to exceed.
WARNING
Only after the first 2000 km (1243 mi) of running-in you can expect the best performance levels from the
vehicle.
Keep to the following indications:
• Do not open the throttle completely if the speed is low, both during and after the running-in.
• During the first 100 km (62 mi) pull the brakes with caution, avoiding sharp and prolonged brakings. This ensures a
correct bedding-in of the pads on the brake disc.
• During the first 1000 km (621 mi) never exceed 5000 rpm (see table).
WARNING
After the first 1000 km (621 mi), Dealer carry out the checks indicated in the column "After running-in",
see (REGULAR SERVICE INTERVALS CHART), in order to avoid hurting yourself or other people
and/or damaging the vehicle.
• Between the first 1000 km (621 mi) and 2000 km (1243 mi) drive more briskly, change speed and use the
maximum acceleration only for a few seconds, in order to ensure better coupling of the components; never exceed
6000 rpm (see table).
• After the first 2000 km (1243 mi) you can expect better performance from the engine, however, without exceeding
the maximum allowed [7600 rpm].
Engine maximum rpm recommended
Mileage km (mi) rpm
0÷1000 (621) 5000
1000÷2000 (621÷1243) 6000
over 2000 (1243) 7600
1 - 12
NEVADA 750 i.e.
1.5. LOCATION OF SERIAL NUMBERS
1.5.1. LOCATION OF SERIAL NUMBERS
These numbers are necessary for vehicle registration.
IMPORTANT: Altering the identification numbers of vehicle
or engine is a legal offence punishable by heavy fines and
penalties. In addition, altering the frame number (VIN) results
in immediate warranty invalidation.
The serial number is composed of numbers and letters as
shown in the following example.
ZGULM00004MXXXXXX.
GENERAL INFORMATION
Key:
ZGU: WMI code (World Manufacture Identifier).
LM: model;
000: version variant;
0: free digit
4 year of manufacture (variable) (4 – for 2004)
M: production plant;
XXXXXX: 6-figure sequential number;
FRAME NUMBER
The frame number (Vehicle Identification Number) is
punched on the right-hand side of the headstock.
ENGINE NUMBER
The engine number is punched on the right hand side of the
engine next to the oil level plug.
1-13
NEVADA 750 i.e.
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE 2
2 - 1
PERIODIC MAINTENANCE
NEVADA 750 i.e.
SUMMARY
2.1. GENERAL TECHNICAL INFORMATION ......................................................................................................... 3
2.1.1. TECHNICAL DATA.................................................................................................................................... 3
2.1.2. PERIODIC MAINTENANCE CHART ......................................................................................................... 6
2.1.3. TABLE OF LUBRICANTS.......................................................................................................................... 8
2.1.4. TIGHTENING TORQUES.......................................................................................................................... 9
2.1.5. SPECIAL TOOLS .................................................................................................................................... 10
2.1.6. LOCATION OF MAIN PARTS.................................................................................................................. 12
2.1.7. LOCATION OF CONTROLS / INSTRUMENTS....................................................................................... 14
2.2. MAINTENANCE OPERATIONS ..................................................................................................................... 15
2.2.1. ENGINE OIL AND FILTER CHANGE ...................................................................................................... 15
2.2.2. CLEANING THE AIR FILTER .................................................................................................................. 16
2.3. SYSTEMS LAYOUT ....................................................................................................................................... 18
2.3.1. SYSTEMS LAYOUT ................................................................................................................................ 18
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NEVADA 750 i.e.
PERIODIC MAINTENANCE
2.1. GENERAL TECHNICAL INFORMATION
2.1.1. TECHNICAL DATA
ENGINE – TRANSMISSION
ENGINE
Type two-cylinder 4-stroke
Number of cylinders two
Cylinder layout: 90° V
Pistons forged, two compression rings, one oil control ring
Bore 80 mm (3.15 in)
Stroke 74 mm (2.91 in)
Total displacement 744 cm3 (45.4 cuin)
Cooling air
Air cleaner dry cartridge type
Compression ratio 9.6:1
Maximum horsepower (CE correction) 35.5 kW at 6800 rpm
Maximum torque (CE correction) 54.7 Nm at 3600 rpm
Engine idling speed 1100 ± 100 rpm
TIMING
Timing diagram: 2 valves with push-rods and rockers
intake valve opens 18° B.T.D.C.
intake valve closes 50° A.B.D.C
exhaust valve opens 53° B.T.D.C.
exhaust valve closes 15° A.B.D.C
Values valid with clearance between rockers
and valve of
FUEL SUPPLY
Type Electronic injection (Weber – Marelli)
Choke Ø 36 mm (1.417 in)
Fuel Premium grade unleaded petrol, min. O.N. 95 (N.O.R.M.) and 85
STARTING
EXHAUST
DRIVE
- clutch dry single disc with cush drive
- primary drive gear-type, ratio: 16/21 = 1:1.3125
- transmission 5 gears
- gear ratios:
1st 11/26 = 1:2.3636
2nd 14/23 = 1:1.6429
3rd 18/23 = 1:1.2778
4th 18/19 = 1:1.0556
5th 20/18 = 1:0.9
- final drive cardan shaft type
- ratio 8/33 = 1:4.825
Lubrication Pressure system, valve adjustment, lobe pump
0,15 mm (0.0059 in) opens
0,20 mm (0.00787 in) closes
(N.O.M.M.).
electric
Three-way manifold with catalyser
2 - 3
PERIODIC MAINTENANCE
VEHICLE
FRAME
Type Detachable tubular duplex cradle with high yield strength
Trail 138 mm (5.43 in)
Rake 27.5°
SUSPENSION
Front MARZOCCHI 40 mm (1.57 in). hydraulic telescopic fork
Front wheel travel 130 mm (5.12 in)
Rear swing arm in light cast alloy with two dampers, spring adjustable for
Rear wheel travel 100 mm (3.94 in)
BRAKES
Front Stainless steel 320 mm (12.6 in) floating disc with 4 differentiated and
Rear Stainless steel 260 mm (10.24 in) disc
Brake master cylinder diameter:
- front brake Ø 13 mm (0.512 in)
- rear brake Ø 12 mm (0.47 in)
Calliper piston diameters:
- front calliper Ø 34/30 mm (1.34/1.18 in)
- rear calliper Ø 32 mm (1.26 in)
Total friction surface area:
- front 21,3 cm2 (3.3 in2)
- rear 16,1 cm2 (2.5 in2)
Brake pads compound Frendo 222
WHEELS
Type spoke-type for tube tyres
Front rim 2.50” x 18”
Rear rim 3,50” x 16”
TYRES
Type
- front METZELER ME 33 – Size:100/90 – V18 56V
- rear METZELER ME 55 – Size:130/90 – 16 67V
Inflation pressure 220 Kpa (31.9 PSI)
Inflation pressure with pillion + 30 Kpa (4.35 PSI)
ELECTRICAL SYSTEM
Battery 12 V – 14 Ah
Alternator (with permanent magnet) 12 V – 330 W
Main fuses 30 A
Secondary fuses 3 A – 10 A – 15 A
BULBS
Headlamp low beam / high beam (halogen) 12V – 55/60 W H4
Front parking light 12V – 5 W
Direction indicators 12V – 10 W (RY 10W amber lamp)
Rear parking /brake lights 12V – 5/21 W
Instruments lighting LED
EFI LED
Number plate light 12V – 5 W
WARNING LIGHTS
Neutral LED
Direction indicators LED
Fuel reserve LED
High beam LED
Engine oil pressure LED
pre-load and rebound
opposing pistons
NEVADA 750 i.e.
2 - 4
NEVADA 750 i.e.
PERIODIC MAINTENANCE
SPARK PLUGS
Standard NGK BR8ES
Gap 0,6 – 0,7 mm (0.024 – 0.028 in)
Resistance
DIMENSIONS
Length 2166 mm (85.3 in)
Width 805 mm (31.7 in)
Maximum height 1068 mm (42 in)
Seat height 770 mm (30.3 in)
Ground clearance 209 mm (8.23 in)
Wheelbase 1467 mm (57.8 in)
Dry weight 184 Kg (406 lb)
CAPACITIES
Fuel (reserve included) 14 l (3.7 gal)
Fuel reserve 4 l (1.06 gal)
Engine oil Oil and filter change 1.78 l (0.47 gal)
Transmission oil 170 cm3 (10.37 in3)
Gearbox oil 1000 cm3 (61 in3)
Front fork fluid 400 ± 2,5 cm3 (15.75 ± 0.1 in) (each leg)
Seats 2
Vehicle max. load 180 Kg (397 lb) (rider + pillion + luggage)
ACCESSORIES
Centre stand, side panniers, luggage rack,
tank bag, tall windshield
5 KΩ
2 - 5
PERIODIC MAINTENANCE
2.1.2. PERIODIC MAINTENANCE CHART
OPERATIONS PERFORMED BY THE Official Moto Guzzi Dealer (THAT CAN ALSO BE PERFORMED BY THE
OWNER).
1 = inspect and clean, set or adjust, lubricate or replace as required;
2 = clean;
3= replace;
4= adjust.
IMPORTANT Perform the maintenance operations more often if the vehicle is used in rainy or dusty areas, on uneven
surfaces or on racetracks.
(*) = Bij sportief rijden vervangen om de 3750 km (2343 mi)
(**) = Check every fifteen days or at the recommended intervals.
After running-in
Components
Spark plugs (*) - om de 7500 km 4687 mi: 3
Engine oil filter (*) 3 3 Front fork 1 - 1
Efficiency/aiming of lights - 1 Lights system 1 1 Safety switches 1 1 Brake fluid - 1 Engine oil 3 3 Tyres 1 1 Tyre pressure (**) 4 4 Engine idling speed 4 4 Tightness of battery terminals 1 - Cylinder head screws torque 4 - Engine oil pressure LED each time engine is started: 1
Brake pads 1 before long trips and every 2000 km (1250 mi):1
[1000 km (621
mi)]
Every 7500 km
(4687 mi) or
12 months
Every 15000 km (9375 mi)
or 24 months
NEVADA 750 i.e.
2 - 6
NEVADA 750 i.e.
OPERATIONS TO BE PERFORMED BY THE Official Moto Guzzi Dealer
1 = inspect and clean, set or adjust, lubricate or replace as required;
2 = clean;
3= replace;
4= adjust.
IMPORTANT Perform the maintenance operations more often if the vehicle is used in rainy or dusty areas, on uneven
surfaces or on racetracks.
(*) = Bij sportief rijden vervangen om de 3750 km (2343 mi)
(**) = Check every fifteen days or at the recommended intervals.
After running-in
Components
CO emissions at idle speed - 1 Transmission cables and controls 1 1 Steering bearings and play 1 1 Wheel hub bearings - 1 Brake discs 1 1 Air cleaner - 1 3
General running of the vehicle 1 1 Braking systems 1 1 Brake fluid Every two years: 3 or every 20000 km (12427 mi)
Transmission oil 3 3 Front fork fluid after the first 7500 km (4687 mi) and every 22500 km (14000 mi)
Fork oil seals after the first 30000 km (18750 mi) and every 22500 km (14000 mi)
Brake pads every 2000 km (1243 mi): 1 - If worn: 3
Valve clearance adjustment 4 4 Wheels/Tyres 1 1 Tightening torque of nuts and bolts 1 1 Tightness of battery terminals 1 - Tightness of Nipples/spokes 4 4 Cylinder timing 1 1 Suspension and ride height 1 - 1
Final drive transmission oil 3 3 Fuel lines - 1 every four years: 3
Brake lines - 1 every four years: 3
Clutch wear (*) - 1 -
[1000 km (621
mi)]
thereafter: 3
thereafter: 3
Every 7500 km
(4687 mi) or
12 months
Every 15000 km (9375 mi)
or 24 months
PERIODIC MAINTENANCE
2 - 7
PERIODIC MAINTENANCE
2.1.3. TABLE OF LUBRICANTS
LUBRICANT PRODUCT
Engine oil
Transmission oil
Gearbox oil
Front fork fluid
Bearings and other lubrication points
Battery terminals Use neutral grease or Vaseline.
Brake fluid
RECOMMENDED:
Alternatively, use brand name oil complying with or exceeding CCMC G-4
A.P.I. S.G. specifications.
RECOMMENDED:
RECOMMENDED:
RECOMMENDED:
FORK 5W or
RECOMMENDED:
GREASE SM2.
As an alternative to recommended grease, use top brand rolling bearing
grease that will resist a temperature range of -30°C…+140°C, with dropping
point 150°C…230°C, high corrosion protection, good resistance to water
and oxidisation.
RECOMMENDED:
compatible with DOT 5) or BRAKE 5.1 DOT 4 (the brake circuit is
also compatible with DOT 5)
As an alternative to the recommended brake fluid, use brake fluids
complying with or exceeding SAE J1703, NHTSA 116 DOT 4, ISO 4925
synthetic brake fluid specifications.
IMPORTANT Use new brake fluid only. Don't mix different brands or types
of brake fluids unless you have ascertained their compatibility.
RACING 4T
TRUCK GEAR 85 W 140
ROTRA MP/S 80 W 90
F.A. 5W or F.A. 20W, alternatively use
FORK 20W.
BIMOL GREASE 481, AUTOGREASE MP or
Autofluid FR. DOT 4 (the brake circuit is also
NEVADA 750 i.e.
2 - 8
NEVADA 750 i.e.
PERIODIC MAINTENANCE
2.1.4. TIGHTENING TORQUES
DESIGNATION
ENGINE CONNECTING PARTS
Front tie rod nut 45
Nut for long and short screws 45
Clutch housing cover to engine fixing screws 25
REAR TRANSMISSION
Bevel pinion to case fixing nut 100
Bevel gear to hollow shaft fixing screws 42
Cover to transmission case fixing screws 25
FRAME
Semi-cradle, frame cradle fixing screws 45
FRONT SUSPENSION
Centre stand to frame fixing screws 10
Lock nut 30
Fork head fixing screws 45
Fork base fixing screws 45
Slider to wheel spindle fixing screws 10
REAR SUSPENSION
TIGHTENING
TORQUES
(Nm)
Rear suspension upper and lower sections fixing screws 20
FRONT WHEEL AND BRAKE DISC
Wheel spindle 80
Brake disc to hub fixing screws 25
Brake calliper fixing screws 50
Nipples/spokes 45
REAR WHEEL AND BRAKE DISC
Brake calliper fixing screw 30
Wheel spindle fixing nut 120
Wheel spindle fixing screws on swing arm 45
Brake disc fixing screws 25
Nipples/spokes 45
STEERING
Steering head fixing screw 50
TANK
Cap fixing screws 6
Breather screws 12
BODYWORK
Pillion/rider footpeg support plate fixing screws 25
Brake fixing screw 25
Front mudguard fixing screws 25
Steering ringnut 7
Steering yoke fixing nut 80
2 - 9
PERIODIC MAINTENANCE
2.1.5. SPECIAL TOOLS
NEVADA 750 i.e.
2 - 10
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