Page 1 SERVICE STATION MANUAL 854316 BREVA - V850...
Page 2 Countries. Third party products or services referred to in this manual should be considered only informative and are not binding. Moto Guzzi s.p.a. shall not be liable for any functions or use of these products.
Page 3 In order to optimise customer satisfaction when using our vehicles, Moto Guzzi s.p.a. commits itself to continually improve its products and the relative documentation. The main technical modifications and changes in repair procedures are communicated to all Moto Guzzi Sales Outlets and its International Subsidiaries.
Page 5: Index Of Topics
INDEX OF TOPICS CHAR HARACTERISTICS S-TOOLS PECIAL TOOLS MAIN AINTENANCE ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE P SUPP OWER SUPPLY SUSP USPENSIONS CHAS HASSIS BRAK SYS RAKING SYSTEM BODYW ODYWORK PRE DE DELIVERY...
Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...
Page 7: Safety Rules
BREVA - V850 Characteristics Rules Safety rules Carbon monoxide If you need to keep the engine running while working on the vehicle, please ensure that you do so in an open or very well ventilated area. Never run the engine in an enclosed area. If you do work in an enclosed area, make sure to use a fume extraction system.
Page 8 BREVA - V850 Characteristics Brake and clutch fluid BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAINTED SURFACES. WHEN SERVICING THE BRAKING SYSTEM OR THE CLUTCH SYSTEM, PROTECT THESE COM- PONENTS WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THESE SYSTEMS.
Page 9: Electrical Connectors
REASSEMBLING COMPONENTS CAUTION BEARINGS MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE, THEY NEED TO BE REPLACED. • Only use ORIGINAL Moto Guzzi SPARE PARTS. • Comply with lubricant and consumables use guidelines. • Lubricate parts (whenever possible) before reassembling them.
Page 10: Vehicle Identification
That is to permit the adequate adjustment of the pad friction material to the brake discs. AFTER THE SPECIFIED MILEAGE, TAKE THE VEHICLE TO AN OFFICIAL Moto Guzzi DEALER FOR THE CHECKS INDICATED IN THE "AFTER RUN-IN" TABLE IN THE SCHEDULED MAINTE- NANCE SECTION TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHI- CLE.
Page 11: Chassis Number
BREVA - V850 Characteristics This number is composed by numbers and letters, as in the example shown below. ZGULPB000YMXXXXXX KEY: ZGU: WMI (World manufacture identifier) code; LP: model; B00: version variation; 0: digit free Y year of manufacture M: production plant (M= Mandello del Lario);...
Page 12 BREVA - V850 Characteristics Specification Desc./Quantity Compression ratio 9.8 :1 Electric starter Engine idle speed 1100 ± 100 rpm Clutch dry, twin disc with hydraulic control Lubrication Pressure-fed, controlled by valves and trochoidal pump Air filter cartridge-type dry filter Cooling Fuel system Electronic injection (Weber .
Page 13 BREVA - V850 Characteristics Specification Desc./Quantity Rear daylight running light/stop light Dashboard lighting License plate light 12V - 5 W Turn indicator warning light ABS warning light Neutral gear warning light Alarm warning light Side stand down warning light Low fuel warning light...
Page 14: Wheels And Tyres
BREVA - V850 Characteristics Wheels and tyres WHEELS AND TYRES Specification Desc./Quantity Type hollow 3-spoke rim in chilled cast aluminium alloy Front wheel rim 3.50" x 17" Rear wheel rim 5.50" x 17" Tyres METZELER Roadtec Z6 MICHELIN Pilot Road...
Page 15 BREVA - V850 Characteristics OIL PUMP Name Torque in Nm Oil pump fixing screw - TBEI M6x30 (3) 10 Nm (7.38 lbf ft) - Loctite 243 Oil pump gear nut - M10x1.25 (1) 20 Nm (14.75 lbf ft) Oil delivery pipe screw (1) 17 Nm (12.54 lbf ft)
Page 16: Side Stand
BREVA - V850 Characteristics Name Torque in Nm Left and right footrest plate to chassis upper retainer 20 Nm Right footrest plate to chassis lower retainer 30 Nm Left footrest plate to chassis lower retainer 30 Nm Right/left protection cover retainer...
Page 17: Front Wheel
BREVA - V850 Characteristics FRONT WHEEL Name Torque in Nm Wheel pin nut 80 Nm Disc retainer 30 Nm REAR WHEEL Name Torque in Nm Disc retainer 30 Nm Rear wheel retainer 10.9 110 Nm FRONT BRAKING SYSTEM Name Torque in Nm...
Page 18 BREVA - V850 Characteristics Name Torque in Nm Front mudguard retainer 4 Nm CHASSIS/ FAIRINGS (REAR) Name Torque in Nm Tail section + fairing retainer 4 Nm Tail section to handgrip retainer 4 Nm Net hooks to chassis retainer 25 Nm...
Page 19: Piston Rings
BREVA - V850 Characteristics Piston rings Check the sealing piston rings and the oil scraper. On each piston there are: 1 top piston ring; 1 middle stepped piston ring; 1 oil scraper piston ring. The ends of the fitted piston rings are out of phase.
Page 20 BREVA - V850 Characteristics TAPPET-SEAT COUPLING ON CRANKCASE DATA (PRODUCTION) Specification Desc./Quantity Seats diameter 22.021 - 22.000 mm (0.86697 ÷ 0.86614 inch) Tappet external diameter 21.996 - 21.978 mm (0.86598 ÷ 0.86527 inch) Fitting clearances 0.004 - 0.043 mm (0.00016 ÷ 0.00169 in.)
Page 21: Index Of Topics
INDEX OF TOPICS S-TOOLS PECIAL TOOLS...
Page 22: Special Tools
BREVA - V850 Special tools SPECIAL TOOLS Stores code Description 05.94.86.30 Belt tension tool 05.91.17.30 Front cover insertion cone 05.91.25.30 Gearbox opening 05.92.80.30 Piston ring clamp 05.92.72.30 Timing system cover sealing ring punch 01.92.91.00 Wrench for removing the cover on sump...
Page 23 BREVA - V850 Special tools Stores code Description 05.90.25.30 Gearbox support 19.92.96.00 Graduated dial to control ignition timing 17.94.75.60 Arrow to control ignition timing 12.91.18.01 Tool to lock the flywheel and the starting ring gear 12.91.36.00 Tool to remove the flywheel-side flange 10.90.72.00...
Page 24 BREVA - V850 Special tools Stores code Description 14.92.71.00 Tool to fit the sealing ring on the flywheel- side flange 12.91.20.00 Tool to fit the flywheel-side flange togeth- er with seal ring on the crankshaft 19.92.71.00 Tool to fit the seal ring on the flywheel- side flange 14.92.73.00...
Page 25 BREVA - V850 Special tools Stores code Description 30.91.28.10 Clutch body locking 05.90.27.30 Gearbox support 05.90.27.31 Gearbox oil seal buffer 05.90.27.32 Buffer handgrip 05.90.27.33 Ball joint sealing buffer 05.90.27.34 Wrench for pinion ring nut 05.90.27.35 Pinion oil seal buffer S-TOOLS - 25...
Page 26 BREVA - V850 Special tools Stores code Description 05.90.27.36 Bevel gear pair support GU14912603 Hook spanner for fixing ring nut of the clutch shaft internal body S-TOOLS - 26...
Page 27: Maintenance
INDEX OF TOPICS MAIN AINTENANCE...
Page 28: At Every Start-Up
BREVA - V850 Maintenance Maintenance chart NOTE CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VE- HICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS, OFF ROAD OR FOR TRACK USE. AT EVERY START-UP Action Engine oil pressure warning light - check and clean, adjust, grease or replace if necessary...
Page 29: Transmission Fluid
BREVA - V850 Maintenance Action Steering bearings and steering clearance - Check and clean, adjust, grease or replace if necessary. Wheel bearings - Check and clean, adjust, grease or replace if necessary Disc brakes - Check and clean, adjust or replace if necessary...
Page 30: Engine Oil
BREVA - V850 Maintenance Replacement CAUTION THE UNIT MUST BE HOT WHEN THE OIL IS CHANGED AS UNDER SUCH CONDITIONS OIL IS FLUID AND THEREFORE EASY TO DRAIN. NOTE RIDE SOME km (miles) TO WARM UP ENGINE OIL • Place a container with + 400 cm³ (25 cu in) capacity under the drainage plug (3).
Page 31 BREVA - V850 Maintenance • Remove the dipstick (1). • Check oil level on the dipstick (1). • The oil level is correct when it close to the "MAX" mark. MAX = maximum level MIN = minimum level Add engine oil if required: •...
Page 32: Engine Oil Filter
BREVA - V850 Maintenance • Screw and tighten the drainage plug (2). • Pour new oil until it goes above the minimum level marked "MIN". Engine oil filter • Unscrew and remove the engine oil fil- ter from its seat.
Page 33: Air Filter
BREVA - V850 Maintenance • Top-up with oil until it reaches the dip- stick opening (1). CAUTION DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCE TO THE FLUID. WHEN USING A FUNNEL OR ANY OTHER EL- EMENT, MAKE SURE IT IS PERFECTLY CLEAN.
Page 34: Checking The Valve Clearance
BREVA - V850 Maintenance • Remove the oil breather pipe. • Unscrew and remove the five screws. • Lift the filter casing cover. • Remove the acoustic insulation panel. • Remove the air filter. • Cover the inlet duct with a clean cloth so that no foreign bodies could get into.
Page 35: Braking System
BREVA - V850 Maintenance • Remove the fuel tank. • Unscrew and remove the two screws. • Remove the spark plugs protection. • Disconnect both spark plug tubes. • Unscrew and remove the eight screws. • Remove the head cover.
Page 36 BREVA - V850 Maintenance • For the rear brake, keep the vehicle upright so that the fluid in the reservoir is at the same level with the plug. • Make sure that the fluid level in the reservoir is above the "MIN" reference mark:...
Page 37 CHECK BRAKING EFFICIENCY. IN CASE OF EXCESSIVE TRAVEL OF THE BRAKE LEVER OR POOR PERFORM- ANCE OF THE BRAKING SYSTEM, TAKE YOUR VEHICLE TO AN Official Moto Guzzi Dealer, AS IT MAY BE NECES- SARY TO PURGE THE AIR IN THE SYSTEM. MAIN - 37...
Page 38: Electrical System
INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 39 BREVA - V850 Electrical system Components arrangement Key: 1 Coil 2 Instrument panel 3 Fuel pump 4 Injector ELE SYS - 39...
Page 40: Electrical System Installation
BREVA - V850 Electrical system 5 Throttle valve potentiometer 6 Fall sensor 7 Rear light 8 Battery 9 Main fuses 10 Lambda probe 11 Intake air temperature sensor 12 Engine revolution sensor 13 Auxiliary fuses 14 Head temperature sensor 15 Engine control unit...
Page 41: General Wiring Diagram
BREVA - V850 Electrical system General wiring diagram Legenda: 1. Connettori multipli 2. Interruttore frizione 3. Rele' avviamento 4. Rele' luci ELE SYS - 41...
Page 42 BREVA - V850 Electrical system 5. Devioluci destro 6. LED illuminazione pulsante HAZARD 7. Pulsante HAZARD 8. Claxon 9. Devioluci sinistro 10.Termistore temperatura aria cruscotto 11.Cruscotto 12.Commutatore a chiave 13.Antenna immobilizer 14.Manopole riscaldate 15.Comando manopole riscaldate 16.Indicatore di direzione posteriore destro 17.Fanale posteriore (a LED)
Page 43: Checks And Inspections
BREVA - V850 Electrical system 43.- 44.Candela cilindro sinistro 45.Doppia bobina cilindro destro 46.Doppia bobina cilindro sinistro 47.Iniettore destro 48.Iniettore sinistro 49.Sensore di velocità 50.Sensore di caduta 51.Pick up volano 52.Schermatura cavo pick up 53.Centralina E.C.U. 54.Indicatore di direzione anteriore sinistro 55.Lampada luce di posizione...
Page 44: Enter New Code
BREVA - V850 Electrical system Dashboard Diagnosis Changing the CODE If you know the code, just enter it and then a new code that will be automatically stored in the memory. If the vehicle is new, the user code is: 00000 Resetting the CODE This function is used to set a new code when the old one is not available;...
Page 45 BREVA - V850 Electrical system Low Battery Error ECU 20 Lambda Probe Error ECU 21 Coil 1 Error DC V DC ECU 22 Coil 1 Error DC Gnd ECU 23 Coil 2 Error DC V DC ECU 24 Coil 2 Error DC Gnd ECU 25...
Page 46 Use the Ditech connector in the Axone 2000 Apri- lia-Moto Guzzi package to connect to the Axone cable. KEY CHANGE FUNCTION This function can be used: 1) if one key is lost;...
Page 47: Checking The Stator
BREVA - V850 Electrical system Checking the stator Single-phase generator with regulated voltage Maximum load 40A (550W) Charging voltage 14.2 - 14.8 V (5000 rpm) Start-up system check pick-up input about 100 A level indicators Petrol pump: Input: 3.5 A (to be measured between pins 1 and...
Page 48: Front Headlamp
BREVA - V850 Electrical system Lights list FRONT HEADLAMP Tail light: 12V - 5W Low-beam light: 12 V - 55 W H7 High-beam light: 12 V - 65 W H9 REAR LIGHT Fuses AUXILIARY FUSES A - Stop, horn, Hazard button illumination, light re- lay coil (15 A).
Page 49: Main Fuses
BREVA - V850 Electrical system MAIN FUSES 1 - From battery to voltage regulator (30 A). 2 - From battery to key and auxiliary fuses C - D (30 A). NOTE THERE IS ONE SPARE FUSE. Control unit Model: Magneti Marelli IAW 5 AM2...
Page 50 BREVA - V850 Electrical system 25 Engine revolution sensor signal 26 Not used 27 Not used 28 Left cylinder injector control 29 Ignition potentiometer power supply 30 Not used 31 Not used 32 Ignition potentiometer negative 33 Not used 34 Revolution sensor anti-jamming cable...
Page 51: Speed Sensor
BREVA - V850 Electrical system 23 Not used 24 Vehicle speed signal input 25 Not used 26 Not used 27 "Engine stop" signal input 28 Ignition signal input 29 CAN - L line (ccm/instrument panel) 30 Not used 31 Not used...
Page 52: Engine Rpm Sensor
BREVA - V850 Electrical system Engine rpm sensor Measures the engine revolution speed and each cylinder timing in relation to the TDC Inductive type sensor, with three-way connector: • positive voltage pin; • negative voltage pin: resistance from 650 to 720 Ohm (to be measured be- tween pins 1 and 2);...
Page 53: Air Temperature Sensor
BREVA - V850 Electrical system Specification Desc./Quantity Resistance at +10 °C (50 °F) 5.970 kOhm Resistance at +20 °C (68 °F) 3.750 kOhm Resistance at +30 °C (86 °F) 2.420 kOhm Resistance at +40 °C (104 °F) 1.600 kOhm Resistance at +50 °C (122 °F) 1.080 kOhm...
Page 54: Engine Oil Pressure Sensor
BREVA - V850 Electrical system Injector Resistance 14 Ohm ± 2 Ohm measured at 20 °C (68 °F) Coil Characteristic Primary resistance: 0.9 - 1.1 Ω (measured between pins 1 and 15) Secondary resistance: 6.5 - 7.2 KΩ. Engine oil pressure sensor...
Page 55: Bank Angle Sensor
BREVA - V850 Electrical system Bank angle sensor Normally open contact, 62 kOhm resistance, with vehicle upright (straight sensor); Closed contact, 0 Ohm resistance, when the sensor is turned by 90° with respect to its fitting position. Air temperature sensor - instrument panel...
Page 56: Heated Handgrip Control
BREVA - V850 Electrical system 15 ANTITHEFT DEVICE LED (IF CONNECTED) 16 SELECT 3 17 SENSORS EARTH CONNECTION 18 GENERAL EARTH CONNECTION 19 GENERAL EARTH CONNECTION 20 GENERAL EARTH CONNECTION 21 + BATTERY 22 + BATTERY 23 LOW-BEAM LIGHT RELAY ACTIVATION...
Page 57: Index Of Topics
INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 58: Removing The Engine From The Vehicle
BREVA - V850 Engine from vehicle Removing the engine from the vehicle • To remove the engine block, first re- move the air filter casing, the oil pan guard and disconnect the battery. • Remove the fork and the bevel gear pair.
Page 59 BREVA - V850 Engine from vehicle • Disconnect the idle motor connector. • Disconnect the engine temperature sensor connector. • Disconnect the throttle valve position sensor connector. ENG VE - 59...
Page 60 BREVA - V850 Engine from vehicle • Disconnect the revolution sensor con- nector. • Disconnect the alternator connector. • Disconnect the neutral sensor connec- tor. ENG VE - 60...
Page 61 BREVA - V850 Engine from vehicle • Unscrew and remove the two screws. • Remove the starter motor protection. • Unscrew and remove the screw. • Disconnect the earth leads. • Disconnect the starter motor connec- tors. ENG VE - 61...
Page 62 BREVA - V850 Engine from vehicle • Disconnect the Lambda probe connec- tor. • Place a container to collect the oil. • Open the clutch bleed pipe. • Drain clutch oil completely. • Unscrew and remove the screw fixing the oil clutch pipe and collect the wash- •...
Page 63 BREVA - V850 Engine from vehicle • Unscrew and remove the lower pin nut and collect the washer. • Remove the lower pin and collect the washer. • Remove the centre stand. • Loosen the clamp. ENG VE - 63...
Page 64 BREVA - V850 Engine from vehicle • Unscrew and remove the screws and collect the washers. • Remove the exhaust manifolds. • Remove the catalytic converter. • Place the engine service stand. • Operating from both sides, unscrew and remove the front fixing screw.
Page 65 BREVA - V850 Engine from vehicle • Unscrew and remove the two screws fixing the oil vapour union tube. • Move the oil vapour union tube aside. • Helped by a second operator, unscrew and remove the engine upper fixing nut and collect the washer.
Page 66 BREVA - V850 Engine from vehicle Installing the engine to the vehicle • Fasten the vehicle chassis to a hoister and lift the engine to place it in its po- sition. • During this operation, restore the oil pressure transmitter connection.
Page 67 BREVA - V850 Engine from vehicle • Operating from both sides, tighten the front fixing screw. • Fit the catalytic converter. • Fit the exhaust manifolds. • Fit the washers and tighten the nuts. ENG VE - 67...
Page 68 BREVA - V850 Engine from vehicle • Tighten the clamp. • Fit the centre stand. • Insert the lower pin and its washer. • Fit the washer and tighten the engine lower fixing nut to the specified torque. ENG VE - 68...
Page 69 BREVA - V850 Engine from vehicle • Connect the horn connectors. • Fasten the clutch oil pipe with the screw and its washers. • Fit the clutch bleed pipe. • Fill up the clutch system. • Connect the Lambda probe connector.
Page 70 BREVA - V850 Engine from vehicle • Fit the starter motor connector. • Screw the nut and place the rubber cover. • Fit the earth leads. • Tighten the screw. • Fit the starter motor protection. • Tighten the two screws.
Page 71 BREVA - V850 Engine from vehicle • Connect the neutral sensor connector. • Connect the alternator connectors. • Connect the revolution sensor connec- tor. ENG VE - 71...
Page 72 BREVA - V850 Engine from vehicle • Connect the throttle valve position sen- sor connector. • Connect the engine temperature sen- sor connector. • Connect the idle motor connector. • Correctly fit the throttle cables, adjust- ing clearance. ENG VE - 72...
Page 73 BREVA - V850 Engine from vehicle • Connect the injector connectors. • Connect the four spark plug tubes. • Refit the entire fork, reaction rod, con- necting rod assembly, brake calliper and the rear wheel. ENG VE - 73...
Page 74: Index Of Topics
INDEX OF TOPICS NGINE...
Page 75 BREVA - V850 Engine Gearbox Diagram KEY: 1. Ball bearing 2. Circlip ENG - 75...
Page 76 BREVA - V850 Engine 3. Shim washer 4. Pin 5. Desmodromic compl. 6. Ball bearing 7. Spring 8. Spacer 9. Circlip 10. Fifth wheel 11. Linking pin 12. Gear 13. Circlip 14. Shoulder washer 15. Ball bearing cage 16. Gear 17.
Page 77 BREVA - V850 Engine 41. Transmission gear 42. Ball bearing 43. Gear 44. Gear 45. Ball bearing cage 46. Shoulder washer 47. Circlip 48. Gear 49. Circlip 50. Gear 51. Main shaft 52. Transmission gear 53. Ring nut 54. Washer 55.
Page 78: Removing The Gearbox
BREVA - V850 Engine Removing the gearbox • Remove the starter motor. • Make sure the transmission is in idle. • Undo and remove the screw and re- move the gearbox lever. • Unscrew and remove the cap. • Place a container of suitable capacity under it, unscrew and remove the cap and then bleed all gearbox oil.
Page 79: Gearbox Shafts
BREVA - V850 Engine • Unscrew and remove the two screws. • Unscrew and remove the screw. • Remove the gearbox. See also Removing the starter motor Replacement Gearbox shafts ENG - 79...
Page 80 BREVA - V850 Engine Disassembling the gearbox • Remove the gearbox. • Place the gearbox on the specific gearbox support tool and on a vice. Specific tooling 05.90.25.30 Gearbox support • Unscrew and slide off the odometer gear and collect the abutment washer that is inside the gearbox.
Page 81 BREVA - V850 Engine • Slide off the two bushings (1) and re- move the rod (2), collect the bushing (3). • Fold the washer fins. • Using the adequate ring nut spanner and the clutch body locking tool, unscrew and remove the ring nut, and collect the clutch internal body.
Page 82 BREVA - V850 Engine • Release the spring. • Pressing the selector, slide off the whole transmission lever. • Unscrew and remove the threaded ref- erence pin. • Use rubber bands to tie down the trans- mission shaft unit and extract it.
Page 83 BREVA - V850 Engine • Remove the bearings from the gearbox if necessary. • Once the transmission shaft unit is in on a bench, remove the rubber bands, being careful with the group. • Detach the shafts and label the forks before removal.
Page 84 BREVA - V850 Engine • Replace bearings if necessary and re- move the clutch shaft. Removing the primary shaft • Remove the main shaft. • Operate on the main shaft from the second gear side. ENG - 84...
Page 85 BREVA - V850 Engine • Remove the gear of the second gear and collect the ball bearing cage. • Remove the gear of the sixth gear and collect the shoulder washer. • Remove the circlip. • Remove the gear of the third and fourth gears.
Page 86 BREVA - V850 Engine • Remove the circlip and collect the shoulder washer. • Remove the gear of the fifth gear and collect the ball bearing cage. • Heat the shaft with a specific heater and remove the helical transmission gear.
Page 87 BREVA - V850 Engine • Remove the shoulder washer. • Remove the gear of the second gear and collect the ball bearing cage and the shoulder washer. • Remove the circlip. • Remove the gear of the sixth gear. ENG - 87...
Page 88 BREVA - V850 Engine • Remove the circlip and collect the shoulder washer. • Remove the gear of the fourth gear and collect the ball bearing cage. • Remove the gear of the third gear and collect the ball bearing cage and the shoulder washer.
Page 89 BREVA - V850 Engine • Remove the gear of the fifth gear. • Remove the circlip, the shoulder wash- er and remove the gear of the first gear, collect the ball bearing cage. • Remove the bearing if necessary. See also...
Page 90 BREVA - V850 Engine VEHICLES WITH CHASSIS NUMBER FROM ZGULPB00X6M111111 TO ZGULPB00X6M111397 MAY PRESENT SOME NOISE PROBLEMS AT IDLE SPEED. TO REDUCE THIS NOISE, ON THE CLUTCH SHAFT FIT TWO SHAPED WASHERS (8) BESIDES THE ONE ALREADY PRESENT IN THE ASSEMBLY...
Page 91: Checking The Secondary Shaft
BREVA - V850 Engine Checking the secondary shaft Measure the coaxiality of the transmission shaft with a dial gauge and a centring device and re- place it if not complying with specifications. Characteristic Shaft coaxiality limit 0.08 mm (0.0031 in) Check transmission gears for signs of pitting and wear and replace damaged gears if necessary.
Page 92: Assembling The Gearbox
BREVA - V850 Engine • Check the transmission fork move- ment and if it is not regular, replace the transmission forks. See also Disassembling the gearbox Fitting the primary shaft NOTE TO REFIT, FOLLOW THE SAME INSTRUCTIONS AS FOR REMOVAL BUT IN REVERSE ORDER.
Page 93: Removing The Flywheel
BREVA - V850 Engine See also Disassembling the gearbox Flywheel Removing the flywheel • Remove the clutch. • Position the locking tool on the flywheel and loosen the six flywheel fixing screws operating diagonally and in stages. • Remove the locking tool.
Page 94: Installing The Flywheel
BREVA - V850 Engine Installing the flywheel • Position the flywheel. NOTE RESPECT THE FLYWHEEL POSITIONING REFERENCES. CAUTION THE SCREWS MUST BE REPLACED WITH NEW ONES AT THE FOLLOWING REFITTING AS THEY ARE SUBJECT TO HIGH LOADS AND STRESS. •...
Page 95 BREVA - V850 Engine • Remove the cover. • Unscrew and remove the eight screws. • Undo and remove the two screws. • Unscrew the nut and collect the screw. ENG - 95...
Page 96 BREVA - V850 Engine • Loosen the screw. • Loosen the nut and undo the set screw so that the alternator slides down. • Completely loosen and remove the screw. • Remove the belt and the alternator with pulley. ENG - 96...
Page 97: Tensioning The Belt
BREVA - V850 Engine • Using a compressed air gun, unscrew and remove the nut and collect the spacer. • Remove the lower pulley. • Undo and remove the two screws. • Remove the alternator frame. • Remove the sealing ring if necessary.
Page 98: Installing The Generator
BREVA - V850 Engine • Unscrew and remove the spacer. • Unscrew and remove the five fixing screws of the timing system cover. • Remove the timing system cover. • Loosen the set screw lock nut. • Using the belt tensioning tool (code 05.94.86.30), tension the belt to the...
Page 99 BREVA - V850 Engine • Replace the gasket and place the al- ternator frame using the front cover in- sertion cone. • Remove the insertion cone afterwards. Specific tooling 05.91.17.30 Front cover insertion cone • Tighten the two screws. •...
Page 100 BREVA - V850 Engine • Position the alternator and the timing system belt. • Position the screw and pre-tighten it. • Position the screw and tighten the nut. • Using the belt tensioning tool (code 05.94.86.30), tension the belt to the prescribed torque and screw the set screw.
Page 101: Removing The Starter Motor
BREVA - V850 Engine • Tighten the alternator fixing screws. • Tighten the four screws, operating di- agonally and in stages. • Position the timing system cover. • Tighten the five screws, operating in oblique direction and in stages. Starter motor Removing the starter motor •...
Page 102: Disassembling The Clutch
BREVA - V850 Engine • Slide off the starter motor. Clutch side Disassembling the clutch • Remove the gearbox from the engine. • Use the locking tool and the clutch spring compression tool on the fly- wheel. Specific tooling 30.90.65.10 Tool for clutch fitting 12.91.18.01 Tool to lock the flywheel and the...
Page 103 BREVA - V850 Engine Extract from the inside of the engine flywheel: • the clutch plate. • The intermediate plate. • The second clutch plate. • The pressure plate disc cover. ENG - 103...
Page 104: Checking The Clutch Plates
BREVA - V850 Engine • The pressure plate disc with springs. Checking the clutch plates Driven plates Check that the supporting surfaces with the driven plates are perfectly smooth and even and that the external toothing that works inside the flywheel is not damaged, otherwise, replace the plate.
Page 105: Assembling The Clutch
BREVA - V850 Engine Assembling the clutch Insert the components in the clutch bell in the fol- lowing order: • the pressure plate with springs. • Make sure that the reference marked on the pressure plate tooth is aligned with the reference on the flywheel.
Page 106 BREVA - V850 Engine • Remove the locking tool. • Fit the clutch disc. Specific tooling 12.91.18.01 Tool to lock the flywheel and the starting ring gear • The intermediate disc. • The clutch disc. • Place the crown gear aligning its refer- ence with that on the flywheel.
Page 107: Removing The Head Cover
BREVA - V850 Engine • Tighten the eight screws sealing the crown gear to the flywheel to the pre- scribed torque • Remove the special tool for clutch spring compression. Specific tooling 30.90.65.10 Tool for clutch fitting • Insert the pressure plate disc cover.
Page 108: Removing The Cylinder Head
BREVA - V850 Engine • Remove the head cover and collect the gasket. Removing the cylinder head • Remove the rocker rods. • Unscrew and remove the outer spark plug. • Loosen the nut and disconnect the pipes that deliver oil to the head.
Page 109 BREVA - V850 Engine • Unscrew and remove the joint of the pipe that delivers oil to the head and collect the washer. • Undo and remove the two screws and collect the two washers. • Slightly detach the cylinder head and remove the four O-rings.
Page 110: Cylinder Head
BREVA - V850 Engine • Remove the head and collect the gas- ket. Cylinder head Removing the rocker arms NOTE THE FOLLOWING OPERATIONS REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH HEADS. • Remove the head cover. • Rotate the crankshaft to TDC position in com- bustion phase (closed valves) for the left cylinder.
Page 111: Removing The Valves
BREVA - V850 Engine • Remove the rocking levers and collect the three washers. See also Removing the head cover Removing the valves • Remove the head. • Place the special tool on the upper cap and at the centre of the head of the valve to be removed.
Page 112: Checking The Valve Guides
BREVA - V850 Engine Checking the valve guides Use a punch to extract the valve guides from the heads. The valve guides should be replaced only if the clearance between them and the stem cannot be eliminated by simply replacing the valves.
Page 113: Installing The Valves
BREVA - V850 Engine • The planes of contact with the cover and with the cylinder are not scored or damaged so as to compromise a perfect seal. • Check that the clearance between the valve guide holes and valve stanchions is within the prescribed limits.
Page 114 BREVA - V850 Engine 10.90.72.00 Tool for valve removal and refitting NOTE UPON REFITTING, PLACE THE O-RING CORRECTLY ON THE VALVE. • Remove the special tool Installing the rocker arms CAUTION UPON REFITTING, ALWAYS REPLACE THE O-RINGS CAUTION UPON REFITTING, DO NOT INVERT THE POSITION OF THE ROCKING LEVER SUPPORTS SO AS NOT TO COM- PROMISE LUBRICATION.
Page 115 BREVA - V850 Engine • Install the rocking lever rods if they have been previously removed. • Install the rocking lever support and re- place the four O-rings. • Place the four washers and screw the four nuts. • Place the six washers and install the rocking levers.
Page 116: Chain Removal
BREVA - V850 Engine • Rotate the crankshaft to TDC position in combustion phase (closed valves) for the left cylinder. • Tighten the two screws. See also Installing the rods Timing Chain removal • Remove the engine assembly. • Remove the alternator.
Page 117 BREVA - V850 Engine • Unscrew the central sealing nut of the camshaft gear and collect the washer. • Remove the cotter. • Unscrew and remove the central seal- ing nut of the timing system control gear on the crankshaft and collect the washer.
Page 118 BREVA - V850 Engine • Remove the chain tensioner and col- lect the spring. • Slide off the three gears together with the chain. CAUTION BE CAREFUL WITH THE OIL PUMP PULLING COTTER. See also Removing the engine from the vehicle Removing the rods •...
Page 119: Removing The Camshaft
BREVA - V850 Engine Removing the rocker arms Removing the tappets • Remove the engine assembly. • Remove both heads. • Slide off and remove the tappets from their seat on both sides. See also Removing the engine from the vehicle Removing the phonic wheel •...
Page 120: Installing The Camshaft
BREVA - V850 Engine • Unscrew and remove the three screws and collect the washers. • Remove the flange. • Remove the camshaft. See also Chain removal Removing the phonic wheel Removing the tappets Removing the rods Installing the camshaft...
Page 121: Installing The Chain
BREVA - V850 Engine Installing the rods • Install the head if it has been previously removed. • Replace the four O-rings. • Install the two rocking lever rods. Installing the chain For the installation of the three gears and of the timing chain carry out the operations indicated in section "Timing".
Page 122 BREVA - V850 Engine with the fixed reference on the crank- case. • Position the locking tool on the flywheel and tighten the six flywheel sealing screws operating diagonally and in stages. • Fit the clutch. Specific tooling 12.91.18.01 Tool to lock the flywheel and the starting ring gear •...
Page 123 BREVA - V850 Engine • Introduce the belleville spring and the nut to fasten the camshaft gear. • Introduce the washer and the nut to fasten the crankshaft gear. • Turn the oil pump shaft and introduce the gear pulling woodruff key.
Page 124 BREVA - V850 Engine Timing To check distribution timing, follow these instruc- tions: • Obtain a clearance between rocking levers and valves equal to 1.5 mm (0.059 in); • Place the hub for graduated dial and the relative graduated dial on the crankshaft slot, inserting the spacer and fixing it to the shaft with the nut.
Page 125 BREVA - V850 Engine • Rotate the crankshaft until the left cyl- inder piston is actually at the top dead centre (with valves closed). • Reset the dial gauge and make sure the references (on the timing system gears and the engine pinion) are per-...
Page 126 BREVA - V850 Engine • Screw the dial gauge support and then the gauge itself on the right cylinder outer spark plug hole. • With a screw, fix the arrow to the threa- ded hole to the right of the crankcase.
Page 127 BREVA - V850 Engine • Insert a suitable plain washer on the sensor and note its thickness. • Place the sensor on the timing system cover and cause it to make contact with the tone wheel. • Measure the clearance between the fixing plate and the cover with a feeler gauge.
Page 128: Removing The Cylinder
BREVA - V850 Engine Removing the cylinder NOTE THE OPERATIONS DESCRIBED BELOW REFER TO ONE HEAD REMOVING ONLY BUT APPLY TO BOTH HEADS. • Remove the head. • Slide off the gasket. • Slide off the cylinder from the stud bolts, paying attention not to damage the piston.
Page 129: Fitting The Piston
BREVA - V850 Engine • Remove the pin. • Mark the piston crown on the exhaust side so as to remember the refitting po- sition. • Remove the piston. See also Removing the cylinder Fitting the piston NOTE THE OPERATIONS DESCRIBED BELOW REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH HEADS.
Page 130: Installing The Cylinder
BREVA - V850 Engine • Insert the pin. • Insert the pin clip. Installing the cylinder • Fit the piston. • Remove the cloth used to prevent foreign bodies coming into the crankcase. • Turn the rings so that the junction ends are 120 degrees from each other.
Page 131: Installing The Cylinder Head
BREVA - V850 Engine CAUTION UPON REFITTING DO NOT INVERT THE POSITION OF THE CYLINDER GASKET SO AS NOT TO COMPROMISE LU- BRICATION. CAUTION THE NEW LUBRICATION SYSTEM IS VALID FROM EN- GINE N° A111934 ON. • Place the gasket on the cylinder base.
Page 132 BREVA - V850 Engine • Place the two washers and tighten the two screws. • Insert the washer and screw the joint of the pipe that delivers oil to the head . • Screw the threaded cap. ENG - 132...
Page 133 BREVA - V850 Engine • Connect the pipes that deliver oil to the head and screw the nut. • Install the outer spark plug. • Replace the gasket and install the head cover. See also Installing the valves Installing the...
Page 134 BREVA - V850 Engine Installing the head cover • Replace the gasket and fit the head cover. • Place the bushings and cross tighten the eight screws. Crankcase - crankshaft Removing the crankshaft • Remove the connecting rods. • Undo and remove the eight fixing screws and collect the washers.
Page 135 BREVA - V850 Engine • Hold the crankshaft during flange re- moval. • Using the suitable special tool, remove the crankshaft flange. • Remove the sealing ring from the flange, if necessary. Specific tooling 12.91.36.00 Tool to remove the flywheel-side flange •...
Page 136: Connecting Rods
BREVA - V850 Engine Inspecting the crankshaft components Check the surfaces of the main journals; if they are scored or oval-shaped, reface them (observing the undersize charts), and replace the flanges and the main journals. FITTING CLEARANCES Specification Desc./Quantity Between the bearing and the main journal on the timing system 0.028 ÷...
Page 137 BREVA - V850 Engine Before reaming the crankpin, measure the pin diameter comparing it with the maximum wear allowed, as indicated in the figure; this defines what kind of undersizing the bearing should have and to which diameter the pin should be reamed.
Page 138: Installing The Crankshaft
BREVA - V850 Engine Assembling the connecting rod • The references on the connecting rods should be facing the flywheel. • Do not interchange left and right con- necting rods. • Place the connecting rods and the caps (B) on the crankshaft and fasten them with new screws (A).
Page 139 BREVA - V850 Engine • Introduce the crankshaft. • Place the flywheel side crankshaft sup- port flange, taking into account the fit- ting order indicated by the holes. Specific tooling 19.92.71.00 Tool to fit the seal ring on the fly- wheel-side flange •...
Page 140 BREVA - V850 Engine • Unscrew and remove the three screws fixing the oil pump. • Remove the oil pump. Installing • Fit the oil pump. • Tighten the three oil pump fixing screws. • Place the shim washer adequately so that the timing chain do not wear out the crankcase.
Page 141 BREVA - V850 Engine • Unscrew and remove the oil level plug and collect the O-Ring. • Undo and remove the fourteen screws fixing the oil sump to the engine crank- case. • Unscrew and remove the four screws and remove the engine oil sump cover.
Page 142 BREVA - V850 Engine • Unscrew and remove the two screws. • Remove the mesh filter and collect the gasket. • Remove the black flange and collect the gasket. • Unscrew and remove the plug. • Unscrew and remove the pressure re- lief valve plug.
Page 143 BREVA - V850 Engine Refitting the oil sump • Place the pressure relief valve compo- nents correctly. • Screw the pressure relief valve plug. • In case of overpressure, the engine oil goes back into the oil sump through the hole indicated in the picture.
Page 144 BREVA - V850 Engine • Screw the cap. • Place a new gasket and refit the black flange. • Place a new gasket and refit the mesh filter tightening the two screws. • Tighten the two screws. ENG - 144...
Page 145 BREVA - V850 Engine • Place the oil sump cover. • Tighten the four screws. • Refit the oil sump on the base. • Fill engine oil up to the correct level. Blow-by • Loosen the oil return pipe sealing joint and remove the oil return pipe from the crankcase.
Page 146 BREVA - V850 Engine • Remove the two oil breather pipes. • Unscrew and remove the oil return pipe positioning screw. • Release the oil return pipe • Remove the complete blow-by system. ENG - 146...
Page 147: Index Of Topics
INDEX OF TOPICS P SUPP OWER SUPPLY...
Page 148: Circuit Diagram
BREVA - V850 Power supply Circuit diagram Key: 1. Full fuel tank 2. Fuel pipe 3. Throttle body 4. Joint 5. Three-way joint 6. Pipe Injection P SUPP - 148...
Page 149 BREVA - V850 Power supply Diagram Key: 1. Control unit 2. Ignition switch 3. Battery 4. Fuel pump 5. Coils 6. Instrument panel 7. Air temperature sensor 8. Throttle valve position sensor 9. Injectors 10. Engine temperature sensor 11. Crankshaft position sensor 12.
Page 150 BREVA - V850 Power supply 13. Side stand 14. Fall sensor Cylinders synchronisation • With engine off, connect the Navigator tool to the diagnosis connector and to the vehicle battery. • Turn on the scanner. • Screw the joints connecting the vacuometer pipes on the inlet pipe holes.
Page 151 BREVA - V850 Power supply • Turn the key to "OFF" and leave it for at least 30 seconds. • Turn the key back to "ON" and restore the Axone session. • Check that the "Throttle" value reading is 4.7 +/- 0.2°. If the value is incorrect, replace the control unit and repeat the procedure from the start.
Page 152 BREVA - V850 Power supply Recovery function If the signal of the following sensors is interrupted, the control unit determines some values to keep the engine running or it uses a different parameter. The instrument panel and the Axone also signal the problem.
Page 153 BREVA - V850 Power supply Engine parameter reading screen page ENGINE PARAMETER READING This screen page shows the parameters meas- ured by the several sensors (engine revs, engine temperature, etc.) or values set by the control unit (injection time, ignition advance, etc.)
Page 154: Device Status
BREVA - V850 Power supply Device status screen page DEVICE STATUS This screen page shows the status (usually ON/ OFF) of the vehicle devices or the operation con- dition of some vehicle systems (for example, lamb- da probe functioning status).
Page 155: Errors Display
BREVA - V850 Power supply Specification Desc./Quantity Right coil operation for 2.5 m, 5 times Left injector Operation for 4 m, 5 times Right injector Operation for 4 m, 5 times Error clearing By pressing the 'enter' button, the stored errors (MEM) become part of the historical data (STO).
Page 156: Adjustable Parameters
BREVA - V850 Power supply Specification Desc./Quantity CAN line diagnosis <span style="FONT-SIZE: 12pt; FONT-FAMILY: "Times New Roman"; mso-fareast-font-family: "Times New Roman"; mso- ansi-language: IT; mso-fareast-language: IT; mso-bidi-lan- guage: AR-SA">Possible error on line CAN: short circuit or line break or no signal or plausibility error detected.
Page 157 INDEX OF TOPICS SUSP USPENSIONS...
Page 158: Front Fork
BREVA - V850 Suspensions Front Front fork Diagram KEY: 1. Screw 2. Right sleeve 3. Left sleeve 4. Upper bushing 5. Cap 6. Sealing ring 7. Locking ring 8. Dust guard 9. Buffer 10. Washer 11. Screw 12. Pin 13. Complete cover 14.
Page 159: Removing The Fork Legs
BREVA - V850 Suspensions 15. Complete pumping member 16. Ring 17. Lower bushing 18. Stem 19. Preload tube 20. Spring 21. Locking ring 22. Bushing 23. Nut 24. Fifth wheel 25. O-Ring 26. Cap body 27. O-Ring 28. Rigging pin Removing the fork legs •...
Page 160 BREVA - V850 Suspensions • Unscrew the screws fixing the front brake callipers and remove them from their seat. • Support the front part of the vehicle. • Remove the nut fixing the wheel pin. • Collect the sealing washer.
Page 161 BREVA - V850 Suspensions • Remove the wheel pin by inserting a screwdriver in the holes on the pin. • During extraction, support the wheel and then remove it. • Collect the spacer from the front wheel right side. •...
Page 162: Draining Oil
BREVA - V850 Suspensions • Remove the fork stem. Draining oil To drain out the oil follow these operations: • Remove the fork. • Unscrew the complete upper closing cap. Pay attention to the possible thrust that the spring can cause to the loosened cap.
Page 163: Disassembling The Fork
BREVA - V850 Suspensions • Press the stem inside the wheel holder sleeve. • Remove the spring. • Drain out all the oil inside the stem. • Collect the preload tube. NOTE FOR EASY DRAINAGE OF THE OIL INSIDE THE PISTON ROD, PRESS THE STANCHION IN THE WHEEL HOLDER SLEEVE TO PUMP OIL OUT.
Page 164 BREVA - V850 Suspensions • Remove the dust scraper using a screwdriver as a lever. CAUTION BE CAREFUL NOT TO DAMAGE THE SLEEVE RIM AND THE DUST SCRAPER. • Remove the locking ring inside the sleeve using a thin screwdriver.
Page 165: Checking The Components
BREVA - V850 Suspensions Checking the components Stem Check the sliding surface for scorings and/or scratches. These scorings can be eliminated by rubbing them with wet sandpaper (grain 1). If the scorings are deep, replace the stem. Use a dial gauge to check that the stem bending is below the limit value.
Page 166 BREVA - V850 Suspensions Check that there are no damages and/or cracks; otherwise, replace it. Spring Check the spring is in good conditions. Check that the following components are in good conditions: • upper bushing; • lower bushing; • piston.
Page 167 BREVA - V850 Suspensions • O-Ring on the cap. Reassembling the fork CAUTION ALL COMPONENTS MUST BE CAREFULLY WASHED AND DRIED WITH COMPRESSED AIR BE- FORE REFITTING. • Carry out any necessary service oper- ation. • On the stem, fit the entire pumping unit together with counter spring and ring.
Page 168 BREVA - V850 Suspensions • Screw the bottom screw and tighten it to the prescribed torque. • Insert the cap and the well lubricated sealing ring in the stem. • Use a suitable inserting tool to push the sealing ring in the fork leg until it stops.
Page 169: Filling Oil
BREVA - V850 Suspensions • Fit the dust scraper. Filling oil • Place the sleeve upright in a vice fitted with protection shoes. • Compress the sleeve in the stem. • Pour part of the fork oil into the sleeve.
Page 170: Installing The Fork Legs
BREVA - V850 Suspensions • Place the cap on the bearing tube tak- ing care not to damage the O-ring. • Then, tighten the cap to the prescribed torque. Installing the fork legs • Insert the fork stem in position.
Page 171 BREVA - V850 Suspensions • Insert the wheel pin so that the stems are aligned. • Tighten the screws on the fork plates to the prescribed torque. • Remove the wheel pin • Place the right side wheel with spacer.
Page 172 BREVA - V850 Suspensions • Tighten the terminal screws (nut side) to lock the wheel pin • Insert the sealing washer onto the wheel axle. • Tighten the wheel axle fixing nut to the specified torque • Make sure that the stanchions are aligned by working with the fork.
Page 173: Steering Bearing
BREVA - V850 Suspensions • Fit the speed sensor. • Tighten the speed sensor screw. • Secure the speed sensor cable har- ness with clamps. • Fit the front mud guard. Steering bearing Adjusting play • Unscrew the upper bolt on the head- stock.
Page 174 BREVA - V850 Suspensions • Operating on both half-handlebars, re- move the two upper fastening screws to the fork plate. • Remove both half-handlebars but keep them connected to the cables. • Operating from both sides, remove the fastening screw of the front cowl under the instrument panel.
Page 175 BREVA - V850 Suspensions • Operating from both sides, remove the screw fastening the light holder fitting to the lower fork plate. • Operating from both sides, remove the screw fixing the fork stems to the upper plate. • Move the light holder fitting a few cen- timetres forward, together with the headlamp and instrument panel.
Page 176 BREVA - V850 Suspensions • Rivet the safety washer on the head- stock. CAUTION UPON REFITTING REPLACE THE SAFETY WASHER WITH A NEW ONE. • Unscrew the upper ring nut. CAUTION UPON REFITTING TIGHTEN THE UPPER RING NUT MAN- UALLY AND THEN FORCE IT SLIGHTLY UNTIL THE NOTCHES ARE ALIGNED WITH THE RING NUTS.
Page 177: Index Of Topics
INDEX OF TOPICS CHAS HASSIS...
Page 178: Swinging Arm
BREVA - V850 Chassis Swinging arm Removing • To remove the swingarm, first remove both footrest supporting plates and the exhaust silencer. • Slide off the rear brake calliper from the disc and release the brake pipe. • Remove the cover.
Page 179 BREVA - V850 Chassis • Remove the clamp from the dust guard cap. • Loosen the two swingarm terminal screws. • Loosen the ring nut. Specific tooling GU14912603 Hook spanner for fixing ring nut of the clutch shaft internal body •...
Page 180 BREVA - V850 Chassis Checking • Check that the universal joint is not damaged, the gear teeth inserting in the sleeve grooves and the grooves on the joint are not deformed or damaged; otherwise, replace the joint. • Check that the rubber bellows are not cut or pierced;...
Page 181 BREVA - V850 Chassis • Use the suitable box-spanner to tight- en the ring nut. Specific tooling GU14912603 Hook spanner for fixing ring nut of the clutch shaft internal body • Tighten the two screws of the swing- arm clamp.
Page 182 BREVA - V850 Chassis • Place the connecting rod assembly on the swingarm. • Insert the screw. • Tighten the fixing nut of the connecting rod assembly. • Place the dust-protection ring between the rim and the cardan shaft taking care to mount it with the collar facing the transmission unit.
Page 183 BREVA - V850 Chassis • Unscrew and remove the nut fixing the reaction rod. • Remove the screw. • Fasten the reaction rod to the chassis with a clamp. • Undo and remove the four screws. • Remove the transmission casing slid- ing off the universal joint.
Page 184 BREVA - V850 Chassis Support unit Removal Remove the bushing (1) with a punch. Turn the support (5) over and remove the other bushing (8). Remove the sealing rings (2) and (7) with a screw- driver. Remove the stop rings (3) and (6) from the support (5) with suitable pliers.
Page 185 BREVA - V850 Chassis Remove the ball joint (4) with a suitable buffer and a rubber hammer. FITTING Fit the stop ring (6) in the support (5) with suitable pliers. Turn the support (5) over. Assemble the ball joint (4) with the buffer and a rubber hammer.
Page 186 BREVA - V850 Chassis Manually assemble the new sealing rings (2) and (7). Assemble the bushing (1). Drive the bushing (1) in with a plastic hammer. Turn the support (5) over and assemble the other bushing (8). Pinion unit Pinion unit Removal Remove the stop ring (1) from the ring nut.
Page 187 BREVA - V850 Chassis Remove the ring nut (2) and remove the sealing ring from the ring nut. NOTE THIS OPERATION DESTROYS THE SEALING RING. Assemble the sealing ring (3) to the ring nut (2) with the buffer CA715855 (see Fig.1) and a ham- mer.
Page 188 BREVA - V850 Chassis Tighten the ring nut (2) with the special spanner (s4) to the prescribe torque. Insert the stop ring (1) in the ring nut (2) in the in- dicated direction. Assembly position of the stop ring (1).
Page 189 BREVA - V850 Chassis Gruppo asse ruota Removal Remove the bearing from the wheel axle with a suitable extractor. Turn the unit over. Remove the bearing from the wheel axle with a suitable extractor. FITTING Heat the bearings to 100°C (212 °F).
Page 190 BREVA - V850 Chassis Turn the unit over. Assemble the bearings to the wheel axle. Casing unit fitting Casing unit fitting Assemble the dowel pins to the casing with the buffer and a hammer. Assemble the casing to the special fastening tool.
Page 191 BREVA - V850 Chassis Insert the support group in the casing. Assemble the cap and the ring. Fit the cap on the support. Fit the clamp. Screw the clamp with the specific pliers. CHAS - 191...
Page 192 BREVA - V850 Chassis Apply the prescribed sealant to the casing. Fit a new sealing ring using the buffer. Lubricate the sealing ring. Assemble two centring stud bolts with M8 thread in the threaded holes of the casing as shown in the picture.
Page 193 BREVA - V850 Chassis Assemble the fixing screws (7). Tighten the screws (7) to the prescribed torque. Remove excessive sealant. Assemble the ring to the casing. Tighten the fixing screws to the prescribed torque. Fit the cap with the washer.
Page 194 BREVA - V850 Chassis Fit the breather with the washer. Screw the breather to the prescribed torque. Fill the transmission with the prescribed oil. Fit the cap with the washer. Screw the cap to the prescribed torque. Assemble the cap with the clamps.
Page 195 BREVA - V850 Chassis Casing unit removal Remove the cover (20). Remove the plug (3) to drain out the oil. Lift the cap (10). CHAS - 195...
Page 196 BREVA - V850 Chassis Remove the clamps (9) and (11). Remove the cap (14). Remove the screws (16). Collect the ring (15). Remove the screws (7). Remove the casing (4). CHAS - 196...
Page 197: Troubleshooting
BREVA - V850 Chassis Remove the clamp (12). Remove the cap (14). Collect the ring (13). Remove the support unit (8). TROUBLESHOOTING Possible Cause Operation 1. Fitting error of the radial seal or seal damaged 2. Sliding 1. Replace the sealing ring and fit it correctly with the suitable...
Page 198 BREVA - V850 Chassis Possible Cause Operation 1. Casing not sealed 2. Closing screws of the casing shells not 1. Open the casing shells, clean the surfaces, seal and reas- tightened to the prescribed torque semble the casing shells 2. Tighten the closing screws to the correct torque 1.
Page 199 BREVA - V850 Chassis • Place the dust-protection ring between the rim and the cardan shaft taking care to mount it with the collar facing the transmission unit. • Place the rear wheel on the swingarm. • Tighten the four screws with their spacers and the dust-protection ring.
Page 200: Index Of Topics
INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 201: Front Brake Pads
BREVA - V850 Braking system Front brake pads Removal • Turn the pins and remove both split pins. • Remove both pins. • Remove the vibration-damping plate. • Extract one pad at a time. CAUTION AFTER REMOVING THE PADS, DO NOT OPERATE THE...
Page 202: Rear Brake Pads
BREVA - V850 Braking system Rear brake pads Removal • Undo and remove the two screws. • Remove the brake calliper from the disc. • Turn the pin and pull out the split pin. • Remove the split pin. •...
Page 203 BREVA - V850 Braking system • Insert the pin. • Place the split pin. • Check the brake fluid level in the res- ervoir. Bleeding the braking system Front Any air trapped in the hydraulic circuit acts as a cushion, absorbing much of the pressure applied by the brake pump and minimising the braking power of the calliper.
Page 204 BREVA - V850 Braking system • Quickly press and release the front brake lever several times and then keep it fully pressed. • Loosen the bleed valve 1/4 of a turn so that the brake fluid flows into the con- tainer.
Page 205 BREVA - V850 Braking system • Remove the rubber protection cover from the bleed valve. • Insert the transparent plastic pipe in the rear brake calliper bleed valve and insert the other end of this pipe into a container to collect the fluid.
Page 206 INDEX OF TOPICS BODYW ODYWORK...
Page 207 BREVA - V850 Bodywork Air box • Remove the fuel tank. • Disconnect the connector from the air temperature sensor. • Remove the oil breather pipe. • Unscrew and remove the two screws from the oil vapour recovery reservoir. •...
Page 208 BREVA - V850 Bodywork • Move the oil vapour recovery reservoir aside. • Unscrew and remove the two front screws from the air filter casing. • Operating from both sides, loosen the clamp and slide off the sleeve from the throttle body.
Page 209 BREVA - V850 Bodywork • Operating from both sides, lift the side fairing to remove it and slide it off the pin. • Operating from both sides, unscrew and remove the two front screws. • Unscrew and remove the rear screw.
Page 210 BREVA - V850 Bodywork • Disconnect the connector. • Disconnect the fuel pipe. • Remove the fuel tank by sliding it off and back. BODYW - 210...
Page 211 INDEX OF TOPICS PRE DE DELIVERY...
Page 212 BREVA - V850 Pre-delivery Carry out the listed checks before delivering the motorcycle. WARNING HANDLE FUEL WITH CARE. Aesthetic inspection - Paintwork - Fitting of Plastic Parts - Scratches - Dirt Tightening torques inspection - Safety fasteners: front and rear suspension unit...
Page 213: Road Test
BREVA - V850 Pre-delivery - Through the diagnosis tool, check that the last mapping version is present in the control unit/s and, if required, program the control unit/s again: consult the technical service website to know about available upgrades and details regarding the operation.
Page 214: Static Test
BREVA - V850 Pre-delivery - Response to throttle control - Stability when accelerating and braking - Front and rear brake efficiency - Front and rear suspension efficiency - Abnormal noise Static test Static check after test drive: - Restarting when warmed up...
Page 215 Air filter: 33 Air temperature sensor: 53, 55 Battery: 46, 51 Brake: 201, 202 Brake pads: 201, 202 Centre stand: Chain: 116, 119–121 Clutch: 89, 92–94, 102, 104, 105 Coil: 54 Crankcase: 19, 134 Crankshaft: 19, 134, 136, 138 Cylinder: 18, 108, 110, 112, 128–131, 135 Desmodromic drum: 91 Display: 155 Electrical system: 12, 39, 40, 212...
Page 216 Maintenance: 8, 28 Oil filter: 32 Oil pressure sensor: 54 Oil sump: 140, 143 Primary shaft: 84, 90, 92 Rear wheel: Recommended products: 20 Secondary shaft: 86, 91, 92 Side stand: Speed sensor: 51 Stand: Start-up: 47 Starter motor: 79, 101 Tank: 208 Transmission: 12, 29 Tyres: 14...

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