MOTO GUZZI Nevada 750 Service Station Manual
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MOTO GUZZI Nevada 750 Service Station Manual

981106
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SERVICE STATION MANUAL
981106
NEVADA 750

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  • Page 1 SERVICE STATION MANUAL 981106 NEVADA 750...
  • 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 CHAR HARACTERISTICS S-TOOLS PECIAL TOOLS MAIN AINTENANCE ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE P SUPP OWER SUPPLY SUSP USPENSIONS CHAS HASSIS PRE DE DELIVERY...
  • Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 7: Safety Rules

    NEVADA 750 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 let the engine run in an enclosed area. If you do work in an enclosed area, make sure to use a fume extraction system.
  • Page 8 NEVADA 750 Characteristics BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAINTED SURFACES. WHEN SERVICING THE BRAKING OR THE CLUTCH SYSTEM PROTECT THESE COMPONENTS WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THESE SYSTEMS. BRAKE AND CLUTCH FLUIDS ARE EXTREMELY HARMFUL FOR YOUR EYES. IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THEM IMMEDIATELY WITH PLENTY OF COLD, CLEAN WATER AND SEEK MEDICAL ADVICE.
  • Page 9 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 NEVADA 750 Characteristics This number consists of numbers and letters, as in the example shown below. ZGULM00004MXXXXXX KEY: ZGU: WMI (World manufacturer identifier) code; LM: model; 000: version variation; 0: digit free 4: variable year of manufacture (4 - for 2004) M: production plant (M= Mandello del Lario);...
  • Page 12 NEVADA 750 Characteristics Specification Desc./Quantity Electric Electric starter Engine idle speed 1100 +/- 100 rpm Intake valve clearance 0.15 mm (0.0059 in) Exhaust valve clearance 0.20 mm (0.0079 in) Clutch dry single-disc clutch with flexible coupling Lubrication Pressure-fed, controlled by valves and trochoidal pump...

  • Page 13: Warning Lights

    NEVADA 750 Characteristics WARNING LIGHTS Specification Desc./Quantity Gear in neutral Turn indicators Fuel reserve High beam light Engine oil pressure Injection check warning light Frame and suspensions CHASSIS Specification Desc./Quantity Type Modular double cradle, high strength steel tubular chassis Steering rake 27.5°...

  • Page 14: Wheels And Tyres

    NEVADA 750 Characteristics Wheels and tyres WHEEL RIMS Specification Desc./Quantity Type with spokes, for tyres with inner tubes Front 2.5''x18'' Rear 3.50 x 17'' TYRES Specification Desc./Quantity Front tyre METZELER LASERTEC Front (size) 100 / 90 - 18 56H TL Front (inflation pressure) 2.2 bar (220 kPa) (31.90 PSI)

  • Page 15: Electric Starting System

    NEVADA 750 Characteristics ELECTRIC STARTING SYSTEM Name Torque in Nm Starter motor fixing screws 25 Nm (18.43 lbf ft) FUEL SUPPLY CONTROL UNIT Name Torque in Nm Injection cap fixing screws M5 4 Nm (2.95 lbf ft) Screws fixing intake pipe to the heads 10 Nm (7.37 lbf ft)

  • Page 16: Front Suspension

    NEVADA 750 Characteristics Name Torque in Nm Lock nut on pin retainer - M20x1 (2) 50 Nm (36.88 lbf ft) - keep the pin firmly in place Swingarm to gearcase retainer - M8 (4) 25 Nm (18.44 lbf ft) - keep the pin firmly in place...

  • Page 17: Fuel Tank

    NEVADA 750 Characteristics HANDLEBAR AND CONTROLS Name Torque in Nm Retainer for handlebar support U-bolts on steering plate - 50 Nm (36.88 lbf ft) M10x60 (2) Handlebar lock U-bolts retainer - M8x30 (2+2) 25 Nm (18.44 lbf ft) Right and left light switch retainer - M5 (2) 1.5 Nm (1.11 lbf ft)
  • Page 18 NEVADA 750 Characteristics Recommended products chart RODOTTI CONSIGLIATI Product Description Specifications AGIP RACING 4T 10W-60 Olio motore In alternativa: 15W - 50. AGIP GEAR MG SAE 85W-140 Transmission oil AGIP GEAR MG/S SAE 85 W-90 Gearbox oil AGIP FORK 7.5W...
  • Page 19 INDEX OF TOPICS S-TOOLS PECIAL TOOLS...

  • Page 20: Special Tools

    NEVADA 750 Special tools SPECIAL TOOLS Stores code Description 19.92.61.00 Punch for seal ring of bevel gear set pin- 19.92.88.00 Bevel gear set alignment pre-fitting tool 19.92.60.00 Punch for gearcase sealing ring 19.90.70.00 Extractor for internal ring on drilled bolt 19.92.75.00...
  • Page 21 NEVADA 750 Special tools Stores code Description 19.92.64.00 Punch for external ring of tapered bearing on bevel gear set pinion holding body 19.92.65.00 Punch for external ring of gearcase bear- 19.92.76.00 Extractor for swinging arm holder bearing on gearbox cover...
  • Page 22 INDEX OF TOPICS MAIN AINTENANCE...

  • Page 23: Maintenance Chart

    NEVADA 750 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. I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE (1) Check and clean and adjust or replace, if necessary, before every journey.
  • Page 24 NEVADA 750 Maintenance Check • Keep the vehicle upright with both wheels on the ground. • Unscrew and remove the cap/dipstick (1). • The level is correct if the oil is close to the hole of the cap/dipstick (1). • If the oil is lower than specified, top-up until it reaches the cap/dipstick hole (1).

  • Page 25: Engine Oil

    NEVADA 750 Maintenance Engine oil Check CAUTION ENGINE MUST BE WARM TO CHECK ENGINE OIL LEVEL NOTE DO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT STANDSTILL TO WARM UP THE ENGINE AND REACH THE OPERATING TEMPERATURE OF ENGINE OIL. OIL IS BEST CHECKED AFTER RUNNING FOR ABOUT 15 KM (10 miles).

  • Page 26: Engine Oil Filter

    NEVADA 750 Maintenance Replacement • Place a container with + 2000 cm³ (122 cu.in) capacity under the drainage plugs (1). • Unscrew and remove the drainage plugs (1). • Unscrew and remove the filler cap (2). • Drain the oil into the container; allow several minutes for oil to drain out com- pletely.

  • Page 27: Air Filter

    NEVADA 750 Maintenance Air filter • Working on both sides, undo and re- move the external air conveyor screw. • Remove both external air conveyors; pay special attention to the hooks. • Working on both sides, undo and re- move the three internal air conveyor screws.

  • Page 28: Braking System

    NEVADA 750 Maintenance • Release the air breather pipe from the clamps. • Slide off the air filter casing cover from the right side of the vehicle. • Remove the air filter. Braking system Level check Brake fluid check •...
  • Page 29 NEVADA 750 Maintenance • Check brake pads and disc for wear. • If the pads and/or the disc do not need replacing, top-up the fluid. Top-up Front brake: • Unscrew the two screws (1) of the brake fluid reservoir (2) using a Phillips screwdriver.
  • Page 30 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 - 30...
  • Page 31 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 32 NEVADA 750 Electrical system ELE SYS - 32...
  • Page 33 NEVADA 750 Electrical system Components arrangement ELE SYS - 33...
  • Page 34 NEVADA 750 Electrical system Key: 1. Instrument panel 2. Coil 3. Fuel pump 4. Throttle potentiometer (TPS) 5. Injector 6. Fall sensor 7. Rear light 8. Battery 9. Main fuses 10.Control unit 11.Speed sensor 12.Intake air temperature sensor 13.Engine speed sensor 14.Head temperature sensor...
  • Page 35 NEVADA 750 Electrical system General wiring diagram Key: 1. Multiple connectors 2. Revolution sensor 3. Oil pressure sensor 4. Left coil ELE SYS - 35...
  • Page 36 NEVADA 750 Electrical system 5. Right coil 6. Spark plugs 7. Left injector 8. Right injector 9. Fuel pump 10.Fuel reserve sensor 11.Main injection relay (polarised) 12.Secondary injection relay 13.Side stand switch 14.Lambda probe 15.Throttle sensor 16.Engine air thermistor 17.Head temperature sensor 18.Voltage regulator...
  • Page 37 NEVADA 750 Electrical system 43.Instrument panel 44.Speed sensor 45.Instrument panel air temperature thermistor 46.Front right turn indicator 47.High-/low-beam bulb 48.Front tail light bulb 49.Front headlamp 50.Front left turn indicator 51.ECU 52.Diagnostics socket Cable colour: Ar orange Az sky blue B blue...
  • Page 38 NEVADA 750 Electrical system • Turn the ignition key to "ON". • Wait for the Key OFF. The next time the vehicle is started, the value will be reset and the word "MAInt" will not be displayed until the next mileage for which maintenance is foreseen.

  • Page 39: Control Unit

    NEVADA 750 Electrical system Fuses FUSE DISTRIBUTION A) High-beam / low-beam lights, start-up (15 A). B) Stop lights, tail lights, horn, turn indicators (15 C) From battery to injection permanent power sup- ply (3 A). D) Injection services (15 A).

  • Page 40: Speed Sensor

    NEVADA 750 Electrical system Battery Characteristic Battery 12V - 12 Ah Speed sensor Function To indicate the vehicle speed by reading the rear wheel rotation speed. Operation / Operating principle Hall effect sensor: a square-wave pulse is gener- ated with voltage between 12V and approximately 0.6 V.
  • Page 41 NEVADA 750 Electrical system - Check correct position of the sensor in its fitting. - Check voltage between PINS 1-3 of the sensor. If there is no voltage, check continuity between PIN 1 of the sensor and PIN 3 of the instrument panel connector.
  • Page 42 NEVADA 750 Electrical system NAVIGATOR: ELECTRICAL ERRORS Throttle - open circuit, shorted to positive / shorted to negative. Error cause • If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 11 of the control unit connector.
  • Page 43 NEVADA 750 Electrical system Engine temperature sensor Function indicates the engine temperature to the control unit so as to optimise carburetion and idle control Operation / Operating principle NTC type sensor (resistance sensor, inversely variable with temperature). Level in electrical circuit diagram:Temperature...
  • Page 44 NEVADA 750 Electrical system • If the circuit is open, shorted to positive: check sensor connector and Marelli control unit connector; if not OK, restore cable harness; if OK, check sensor continuity; if it is not OK, replace the sensor; if it is OK, check continuity between PIN 4 of the control unit connector and the PIN marked by the orange cable of the sensor: restore cable harness if there is not continuity;...
  • Page 45 NEVADA 750 Electrical system • Grey (cable harness side): Ground connection • Pink/black (cable harness side): 0-5 V signal NAVIGATOR:PARAMETERS Air temperature In case of failure, the value set by the control unit is 20 °C (68 °F) NAVIGATOR: ELECTRICAL ERRORS air temperature sensor open circuit, shorted to positive / shorted to negative.
  • Page 46 NEVADA 750 Electrical system Lambda sensor Function In charge of telling the control unit whether the mixture is lean or rich. Operation / Operating principle The Marelli injection control unit reads and inter- prets a voltage generated by the difference in oxy- gen content between the exhaust fumes and the ambient.
  • Page 47 NEVADA 750 Electrical system Lambda check Example value: Open loop / Closed loop Closed loop indicates that the control unit is using the lambda probe signal to keep the combustion as close as possible to the stoichiometric value. NAVIGATOR: ELECTRICAL ERRORS Lambda probe - Generic error.
  • Page 48 NEVADA 750 Electrical system • on the intake manifolds • connector: on injector Electrical characteristics:14.8 Ohm +/- 5% (at 20 °C - 68 °F) Pin-out: 1. Ground connection 2. Power supply 12V NAVIGATOR:PARAMETERS • Left cylinder injection time • Right cylinder injection time...
  • Page 49 NEVADA 750 Electrical system cable between PIN 13 of the control unit connector and PIN 1 of the component and restore the cable harness NAVIGATOR: ACTIVATION Right injector: operation for 4 ms, 5 times The auxiliary injection relay (No. 12 in the wiring diagram, placed under saddle, second relay starting from the front;...
  • Page 50 NEVADA 750 Electrical system Coil Function It controls the ignition spark plug in order to gen- erate the fuel ignition spark. Operation / Operating principle Inductive discharge system. Level in electrical circuit diagram:Coils and in- jectors Location: • centred under the fuel tank.
  • Page 51 NEVADA 750 Electrical system • If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 20 of the control unit connector Troubleshooting • shorted to positive: disconnect the coil connector, set the key to ON, activate the coil with Navigator and check voltage at connector PIN 2: if there is voltage, restore the cable har- ness;...
  • Page 52 NEVADA 750 Electrical system Engine oil pressure sensor Function:it indicates the instrument panel if there is enough oil pressure 0.35 +/- 0.2 bar (5.1 +/- 2.9 PSI) in the engine. Operation / Operating principle: normally closed switch. With oil pressure above 0.35 +/-0.2 bar (5.1 +/- 2.9 PSI) open circuit.

  • Page 53: Bank Angle Sensor

    NEVADA 750 Electrical system Bank angle sensor Function it tells the vehicle position to the control unit. Operation / Operating principle When the sensor is inverted, the circuit is closed to ground: when the Marelli control unit detects this ground, it deactivates the circuit of the fuel pump and the engine start-up circuit, via the injection re- lay.
  • Page 54 NEVADA 750 Electrical system to the PIN marked by the pink/yellow cable: restore the cable harness whose pink/yellow cable will be shorted to ground Air temperature sensor - instrument panel Function It tells the ambient air temperature to the instru- ment panel.
  • Page 55 NEVADA 750 Electrical system strument panel. If voltage continues to be approximately 5V, restore the pink cable (there is a short circuit at + 5V). In case there is a short circuit to ground connection of PIN 12 of the instrument panel connector: Check the earth insulation of the sensor connector pink cable: if there is a connection, restore the cable harness;...
  • Page 56 NEVADA 750 Electrical system black cable (between main injection relay and Marelli control unit) are in shorted to positive: restore the cable harness. If cable harness is OK, replace the Marelli control unit PIN: 1. Throttle position sensor supply - Power out- 2.
  • Page 57 NEVADA 750 Electrical system Dashboard PIN: 1. Right arrow input 2. Set rework input 3. High-beam lights input 4. n.c. 5. n.c. 6. Rear left arrow output 7. Front left arrow output 8. EFI input 9. Left arrow input 10.Neutral input 11.Oil input...
  • Page 58 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 59 NEVADA 750 Engine from vehicle Removing the engine from the vehicle • To remove the engine block, first re- move the superstructure, battery, ex- haust ends, shock absorbers and the rear wheel. • Disconnect de speed sensor and slide off the cable from the cable harness.
  • Page 60 NEVADA 750 Engine from vehicle • Remove the revolution sensor but keep it connected to the cable harness. • Slide the pin, with the split pin, fixing the linkage to the clutch to the engine block and then release the control ca- ble.
  • Page 61 NEVADA 750 Engine from vehicle • Remove the injectors lock and slide in- jectors off there seat on the inlet mani- folds. • Disconnect the spark plug cables from the coils and slide them off the chassis. • Loosen the clamps on the intake mani- folds.
  • Page 62 NEVADA 750 Engine from vehicle • Disconnect the oil breather pipe on the cylinder heads. • Remove the connection of the engine temperature sensor. • Disconnect the starter motor and the lambda probe. ENG VE - 62...
  • Page 63 NEVADA 750 Engine from vehicle • Open the clamp and disconnect the oil breather pipe of the air filter casing. • Disconnect the neutral indicator. • Disconnect the connector of the side stand safety switch and slide off the cable harness from the chassis.
  • Page 64 NEVADA 750 Engine from vehicle • Undo the screw fixing the ground eye- let on the engine block. • Support the vehicle chassis by means of a hoister. • Undo the four Allen head screws fixing the front arms of the chassis to the en- gine cradle.
  • Page 65 NEVADA 750 Engine from vehicle • Remove the upper screws fixing the chassis to the gearbox cover. • Remove the rod fixing the chassis to the gearbox . • Remove the engine: check that during the removal operation, the throttle body sleeves slide off the inlet mani- folds without getting damaged.
  • Page 66 NEVADA 750 Engine from vehicle • During this removal operation, discon- nect the connection of the oil pressure transmitter. Installing the engine to the vehicle • Secure the vehicle chassis by fasten- ing it with a hoister and lift the engine to place it in its position.
  • Page 67 NEVADA 750 Engine from vehicle • Tighten to the prescribed torque the upper screws fixing the chassis to the gearbox cover. • Fasten the chassis front arms to the engine cradle using the four Allen head screws. Tighten them to the prescribed torque.
  • Page 68 NEVADA 750 Engine from vehicle • Connect the neutral indicator. • Insert the oil breather pipe in the air fil- ter casing and lock it with the corre- sponding clamp. • Connect the starter motor and the lambda probe. ENG VE - 68...
  • Page 69 NEVADA 750 Engine from vehicle • Restore the connection of the engine temperature sensor. • Insert the breather pipes on the cylin- der heads and lock them with the spe- cific clamps. • Tighten the clamps on the intake mani- folds.
  • Page 70 NEVADA 750 Engine from vehicle • Insert the injectors in their positions and fit the locking ring, tightening the screw to the prescribed torque. • Connect the spark plug cables on the ignition coils. • Place the clutch linkage and insert the pin on the engine block, locking it with the corresponding split pin.
  • Page 71 NEVADA 750 Engine from vehicle • Refit the swingarm and the bevel gear pair. • Fit the revolution sensor by tightening the screws to the prescribed torque. ENG VE - 71...
  • Page 72 NEVADA 750 Engine from vehicle • Restore the electrical connections of the generator. • Restore the connection of the vehicle speed sensor. ENG VE - 72...
  • Page 73 INDEX OF TOPICS P SUPP OWER SUPPLY...
  • Page 74 NEVADA 750 Power supply Circuit diagram Key: 1. Fuel tank 2. Throttle body 3. Thermistor to check level 4. Fuel filter 5. Fuel delivery pipe 6. Fuel pump unit Injection P SUPP - 74...
  • Page 75 NEVADA 750 Power supply Diagram Key: 1. Control unit position 2. Ignition switch 3. Battery 4. Fuel pump P SUPP - 75...
  • Page 76 NEVADA 750 Power supply 5. Coils 6. Instrument panel 7. Air temperature sensor 8. Throttle valve position sensor 9. Injectors 10.Crankshaft position sensor 11.Engine temperature sensor 12.Lambda Probe 13.Fall sensor 14.Side stand Cylinders synchronisation • With engine off, connect the Navigator tool to the diagnosis connector and to the vehicle battery.
  • Page 77 NEVADA 750 Power supply • Turn the key to "OFF" and leave it for at least 30 seconds. DO NOT TOUCH THE THROTTLE ABUTMENT SCREW OR THE THROTTLE BODY MUST BE RE- PLACED. CHECK THAT THE THROTTLE RETURN CABLE IS NOT TAUT.
  • Page 78 NEVADA 750 Power supply • Take the engine to the prescribed temperature: 70 - 80°C (158 - 176 °F). • Operating the by-pass screws, adjust idle: 1100 ± 50 rpm. Co rate adjustment It is not possible to adjust CO (time of injectors opening) but just resetting the self-adjustable parameters in case the throttle body is replaced because it is worn.
  • Page 79 NEVADA 750 Power supply Specification Desc./Quantity Lambda Probe 300 - 3000 mV (approximate values). Signal when energised that the control unit receives from the lambda probe: inversely proportional to the presence of oxy- gen. Lambda integrator When the control unit uses the lambda probe signal (see the...
  • Page 80 NEVADA 750 Power supply Devices activation screen page DEVICES ACTIVATION This screen page is used to delete errors in the control unit memory and to activate some systems controlled by the control unit. DEVICES ACTIVATION Specification Desc./Quantity Error clearing By pressing the 'enter' button, the stored errors (MEM) become part of the historical data (STO).
  • Page 81 NEVADA 750 Power supply Specification Desc./Quantity Fuel pump relay Possible short circuit in the earth lead, battery or open circuit: the engine does not start. Self-adjustable parameters RAM memory Possible internal control unit error. Also check the control unit supply and earth connections ROM memory Possible internal control unit error.
  • Page 82 INDEX OF TOPICS SUSP USPENSIONS...

  • Page 83: Removing The Front Wheel

    NEVADA 750 Suspensions Front Removing the front wheel • Place the vehicle on a stable support so that the front wheel does not touch the ground. • Remove the brake calliper without dis- connecting the oil pipes • Remove the front wheel.
  • Page 84 NEVADA 750 Suspensions 3. Screw 4. Complete left fork leg 5. Upper bushing 6. Cap 7. Sealing ring 8. Snap ring 9. Dust scraper 10.Bare fork arm 11.Lower bushing 12.Buffer 13.Counter spring 14.Rod 15.Spring 16.Preloading pipe 17.Cap assembly 18.Screw 19.Fork base 20.Ring nut...

  • Page 85: Removing The Fork Legs

    NEVADA 750 Suspensions Removing the fork legs NOTE PAY ATTENTION TO THE TYPE OF FORK FITTED DURING REMOVAL AND FITTING. TWO DIFFERENT SUPPLIES CAN BE FOUND ON THIS MOTORCYLCE, MARZOCCHI OR KAIFA. TO DISTINGUISH BETWEEN THEM IT IS NECES- SARY TO PROCEED WITH THE REMOVAL. THE MARZOC-...
  • Page 86 NEVADA 750 Suspensions • Undo the upper sealing screw. • Undo the lower sealing screw. • Slide off the stem downwards by turning it slightly first in one direction then to the opposite direction. Draining oil To drain out the oil follow these steps.
  • Page 87 NEVADA 750 Suspensions • Unscrew the upper closing cap. Pay attention to the possible thrust that the spring can cause to the loosened cap. KAIFA FORK PROCEDURE • Be careful not to damage the O-Ring during extraction. • Press the bearing tube inside the wheel holder fork leg.
  • Page 88 NEVADA 750 Suspensions • Drain out all the oil inside the stan- chion. NOTE FOR EASY DRAINAGE OF THE OIL INSIDE THE PISTON ROD, PRESS THE STANCHION IN THE WHEEL HOLDER SLEEVE TO PUMP OIL OUT. • Carefully check each part of the stan- chion and make sure that there are no damaged elements.
  • Page 89 NEVADA 750 Suspensions • Remove the dust scraper using a screwdriver as a lever. CAUTION BE CAREFUL NOT TO DAMAGE THE FORK LEG RIM AND THE DUST SCRAPER. • Slide the dust scraper off and upwards. • Remove the locking ring inside the fork leg using a thin screwdriver.
  • Page 90 NEVADA 750 Suspensions Checking the components • Check every component removed from the fork leg, specially: the sealing ring and the dust guard as they are ele- ments that guarantee sealing; replace them if some of them are damaged. •...
  • Page 91 NEVADA 750 Suspensions • Insert the lower sliding bushing in its seat on the bearing tube. • Reassemble the bearing tube in the wheel holder fork leg. • Insert the bearing tube in the wheel holder and push it until it stops.
  • Page 92 NEVADA 750 Suspensions • Insert the cap and the well-lubricated sealing ring on the bearing tube. • Use a suitable inserting tool to push the sealing ring in the fork leg until it stops. • Fit the locking ring. •...
  • Page 93 NEVADA 750 Suspensions Filling oil • Place the sleeve upright in a vice fitted with protection jaws. • Compress the sleeve in the stanchion. • Pour part of the fork oil into the sleeve. • Wait some minutes until the oil fills all the ducts.

  • Page 94: Installing The Fork Legs

    NEVADA 750 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 stem on the vehicle going through the lower plate and the upper plate.
  • Page 95 NEVADA 750 Suspensions • Tighten the screws to the prescribed torque. Steering bearing Adjusting play • Undo and remove the screws and col- lect the U-bolt, holding the handlebar. • Move the handlebar forward, be care- ful not to turn over the front brake fluid reservoir.
  • Page 96 NEVADA 750 Suspensions • Unscrew and remove the central nut. • Remove the upper plate from the front fork. • Adjust the ring nut. • Fit the upper plate on the front fork. SUSP - 96...
  • Page 97 NEVADA 750 Suspensions • Tighten the central nut. • Working from both sides, tighten the screw locking the upper plate to the front fork. • Fit the handlebar. • Fit the instrument panel. Removing • Undo and remove the upper screw.
  • Page 98 INDEX OF TOPICS CHAS HASSIS...
  • Page 99 NEVADA 750 Chassis Swinging arm Removing • Remove the left silencer. • Remove the rear calliper, releasing the brake pipe from the retainers on the swingarm . • Unscrew and remove the fixing screw of the calliper holder. • Remove both rear suspensions.
  • Page 100 NEVADA 750 Chassis • Unscrew and remove the nut and col- lect the washer. • Loosen the wheel pin locking screw. • Remove the wheel pin and collect the spacer. • Remove the rear wheel. CHAS - 100...
  • Page 101 NEVADA 750 Chassis • Unscrew the seal clamp. • Lift the bellows. • Unscrew the nuts. • Loosen the pins so that the oscillating swingarm can be removed from the gearbox. • Remove the shimming washer be- tween the swingarm right arm and the gearbox.
  • Page 102 NEVADA 750 Chassis • Check that the rubber bellows are not cut or pierced; otherwise, replace it. • Check that the swingarm pin threads and the swingarm fixing nuts are not damaged, de- formed or flattened; otherwise, replace them. •...
  • Page 103 NEVADA 750 Chassis • Screw the clamp. • Fit the rear wheel. Bevel gears Removing • Undo the four nuts and collect the washers. • Slide off the gearcase together with the swingarm. CHAS - 103...
  • Page 104 NEVADA 750 Chassis • Slide off the sleeve from the pinion. • Slide off the spring. • Slide off the sealing ring. • Slide off the base. • Slide off the gear. Checking Pinion unit • Remove the housing of the swingarm .
  • Page 105 NEVADA 750 Chassis • Insert the grooved shank of the pinion on the tool and unscrew the nut. • Slide off the spacer. • Slide off the pinion. • Slide off the shim adjustment washer. • Slide off the O-ring.
  • Page 106 NEVADA 750 Chassis • Slide of the tapered bearing from the case. • Slide off the O-ring. • Slide off the spacer. • Slide off the two shim washers. • Slide off the tapered bearing from the case. Checking •...
  • Page 107 NEVADA 750 Chassis • Fit the external ring of the tapered bearings on the bevel pinion holder case using the suitable punch (19926400). • Fit the adjustment shim washer. • Fit the internal ring of the bearing on the pinion using the suitable punch (19926200).
  • Page 108 NEVADA 750 Chassis • Fit both shim washers on the pinion. • Fit the spacer on the pinion. • Fit the O-ring. • Fit the complete pinion on the case us- ing the suitable punch (19926100). • Fit the oil seal.
  • Page 109 NEVADA 750 Chassis • Insert the grooved shank of the pinion on the tool (19907100) and tighten the nut. Casing unit removal • Undo the screws and collect the wash- ers. • Remove the braking disc from the dril- led bolt.
  • Page 110 NEVADA 750 Chassis From the cover, slide off: • The needle bearing. • Remove the internal ring of the needle bearing using a suitable punch (19907000). • Remove the washer. • Remove the washer. • Undo the screws and collect the corre- sponding safety plates.
  • Page 111 NEVADA 750 Chassis • Remove the sealing ring. • Slide off the bearing from the cover us- ing the suitable punch. • Remove the external ring of the needle bearing from the housing using the suitable extractor (19927500). • Remove the sealing ring and the wash- Checking •...
  • Page 112 NEVADA 750 Chassis on the housing; the groove for the circlip on the drilled bolt are not worn, deformed or spoiled; otherwise, replace them. • Check that the sealing ring on the housing is not shattered or is still flexible; otherwise, replace it.
  • Page 113 NEVADA 750 Chassis • Apply suitable colours available in the market on the pinion teeth. • Fit the drilled bolt-crown unit cover and their spacers and gaskets on the hous- ing and provisionally tighten the screws. • On the crown holder drilled bolt, fit a "Universal"...
  • Page 114 NEVADA 750 Chassis • If the contact is like this, the crown is too near the pinion rotation axis: de- tach the crown by increasing spacer thickness. • If the contact is like this, the pinion is too near the rotation axis of the crown:...
  • Page 115 NEVADA 750 Chassis • Fit the washer on the gearcase. • Fit the sealing ring on the housing us- ing the suitable punch (19926000). • Fit the external ring of the needle bear- ing on the housing using the suitable punch (19926500).
  • Page 116 NEVADA 750 Chassis • Fit the internal ring of the needle bear- ing on the drilled bolt using the suitable punch (19927900). • Insert the sealing ring in the drilled bolt. • Fit the drilled bolt on the cover. •...
  • Page 117 NEVADA 750 Chassis • Fit the plates and tighten the screws. • Insert the washer. • Insert the washer. • Fit the O-ring. • Insert the gaskets and the shimming ring on the cover. • Tighten the screws with plates and washers.
  • Page 118 NEVADA 750 Chassis • Fit the braking disc on the drilled bolt by locking the screws with the washers using a torque wrench. • When refitting the bevel pinion case on the transmission, bear in mind that the oil passage grooves with holes should...
  • Page 119 NEVADA 750 Chassis • Correctly insert the stud bolts of the gearcase in the holes of the swingarm . • Screw the nuts with the washers with- out locking them. CHAS - 119...
  • Page 120 NEVADA 750 Chassis Exhaust Key: 1. Right exhaust pipe 2. Left exhaust pipe 3. Expansion chamber 4. Left silencer clamp 5. Gasket 6. Spacer 7. Ring nut 8. Washer 9. Nut 10.Left silencer 11.Right silencer 12.Clamp 13.Right plate 14.Left plate 15.Right silencer clamp...
  • Page 121 NEVADA 750 Chassis 20.Clip 21.Lambda Probe 22.Spacer 23.Cap 24.Gasket 25.Protection 26.U-bolt 27.TBEI screw 28.Bushing 29.Insulating washer Removing the tail pipe The engine and the exhaust system components get very hot and remain in this condition for a certain time interval after the engine has been switched off. Before handling these components, make sure that you are wearing insulating gloves or wait until the engine and the exhaust system have cooled down.
  • Page 122 NEVADA 750 Chassis • Unscrew and remove the lambda sen- sor. CHAS - 122...
  • Page 123 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 124 NEVADA 750 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 125: Road Test

    NEVADA 750 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 126 NEVADA 750 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 127 Air filter: 27 Air temperature sensor: 44, 54 Battery: 38, 40 Bulbs: Coil: 50 Crankcase: Crankshaft: Display: 80 ECU: 56 Electrical system: 12, 32, 34, 124 Engine oil: 25 Engine temperature sensor: 43 Exhaust: 120 Fairings: Fork: 83, 85, 88, 90, 94 Front wheel: 83 Fuel: Fuel pump:...
  • Page 128 Rear wheel: Recommended products: 18 Run/Stop switch: 55 Side stand: Spark plugs: Speed sensor: 40 Stand: Start-up: 38 Tank: Transmission: 12, 23 Tyres: 14 Warning lights: Wiring diagram: 35...

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