MOTO GUZZI Nevada Classic 750 ie 2004 Workshop Manual
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MOTO GUZZI Nevada Classic 750 ie 2004 Workshop Manual

MOTO GUZZI Nevada Classic 750 ie 2004 Workshop Manual

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Summary of Contents for MOTO GUZZI Nevada Classic 750 ie 2004

  • Page 1 Nevada Classic 750 ie workshopmanual...
  • Page 2 INTRODUCTION NEVADA 750 i.e. INTRODUCTION 0 - 1...
  • Page 3 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...
  • Page 4 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.
  • Page 5 INTRODUCTION NEVADA 750 i.e. 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...
  • Page 6 INTRODUCTION 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 ±...
  • Page 7 INTRODUCTION NEVADA 750 i.e. T.C.E.I. = cheese-head Allen screw T.E. = hexagonal head = flat head screw = Twin Spark Ignition UPSIDE- DOWN = inverted fork = Volt = Watt Ø = Diameter 0 - 6...
  • Page 8 GENERAL INFORMATION NEVADA 750 i.e. GENERAL INFORMATION 1 - 1...

  • Page 9: Table Of Contents

    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.

  • Page 10: Structure Of The Manual

    GENERAL INFORMATION NEVADA 750 i.e. 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. •...

  • Page 11: Safety Warnings

    GENERAL INFORMATION NEVADA 750 i.e. 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.

  • Page 12: General Rules

    GENERAL INFORMATION NEVADA 750 i.e. 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 well- aerated 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.
  • Page 13 GENERAL INFORMATION NEVADA 750 i.e. 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.
  • Page 14 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.

  • Page 15: Dangerous Elements

    GENERAL INFORMATION NEVADA 750 i.e. 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.
  • Page 16 GENERAL INFORMATION NEVADA 750 i.e. 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.
  • Page 17 GENERAL INFORMATION NEVADA 750 i.e. 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.
  • Page 18 GENERAL INFORMATION 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.

  • Page 19: Running-In

    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.

  • Page 20: Location Of Serial Numbers

    GENERAL INFORMATION 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.
  • Page 21 PERIODIC MAINTENANCE NEVADA 750 i.e. PERIODIC MAINTENANCE 2 - 1...
  • Page 22 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.

  • Page 23: General Technical Information

    PERIODIC MAINTENANCE NEVADA 750 i.e. 2.1. GENERAL TECHNICAL INFORMATION 2.1.1. TECHNICAL DATA ENGINE – TRANSMISSION ENGINE Type two-cylinder 4-stroke Number of cylinders 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...
  • Page 24 PERIODIC MAINTENANCE NEVADA 750 i.e. 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 pre-load and rebound...
  • Page 25 PERIODIC MAINTENANCE NEVADA 750 i.e. SPARK PLUGS Standard NGK BR8ES 0,6 – 0,7 mm (0.024 – 0.028 in) Resistance 5 KΩ 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)

  • Page 26: Periodic Maintenance Chart

    PERIODIC MAINTENANCE NEVADA 750 i.e. 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;...
  • Page 27 PERIODIC MAINTENANCE 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.

  • Page 28: Table Of Lubricants

    PERIODIC MAINTENANCE NEVADA 750 i.e. 2.1.3. TABLE OF LUBRICANTS LUBRICANT PRODUCT Engine oil RECOMMENDED: RACING 4T Alternatively, use brand name oil complying with or exceeding CCMC G-4 A.P.I. S.G. specifications. Transmission oil RECOMMENDED: TRUCK GEAR 85 W 140 Gearbox oil RECOMMENDED: ROTRA MP/S 80 W 90 Front fork fluid...

  • Page 29: Tightening Torques

    PERIODIC MAINTENANCE NEVADA 750 i.e. 2.1.4. TIGHTENING TORQUES TIGHTENING DESIGNATION TORQUES (Nm) ENGINE CONNECTING PARTS Front tie rod nut Nut for long and short screws Clutch housing cover to engine fixing screws REAR TRANSMISSION Bevel pinion to case fixing nut Bevel gear to hollow shaft fixing screws Cover to transmission case fixing screws FRAME...

  • Page 30: Special Tools

    PERIODIC MAINTENANCE NEVADA 750 i.e. 2.1.5. SPECIAL TOOLS 2 - 10...
  • Page 31 PERIODIC MAINTENANCE NEVADA 750 i.e. Key: Position Tool designation and application Part number Bush for fitting oil seal on secondary shaft 19 92 73 00 Tool for fitting oil seal on timing cover (crankshaft) 19 92 72 20 Valves disassembly / assembly tool 10 90 72 00 Punch for bevel gear pair pinion oil seal 19 92 61 00...

  • Page 32: Location Of Main Parts

    PERIODIC MAINTENANCE NEVADA 750 i.e. 2.1.6. LOCATION OF MAIN PARTS Key: Headlight Left rear-view mirror Fuel filler cap Fuel tank Left side fairing Main fuse-holder (30A) Battery Rider/pillion seat Pillion grab handle 10. Rear left damper 11. Pillion left footpeg 12.
  • Page 33 PERIODIC MAINTENANCE NEVADA 750 i.e. Key: Tail light Rear brake fluid reservoir Secondary fuseholders Glove/tool kit compartment Right side fairing Right rear-view mirror Front brake fluid reservoir Air cleaner Right horn 10. Engine oil filter 11. Rear brake lever 12. Rider right footpeg 13.

  • Page 34: Location Of Controls / Instruments

    PERIODIC MAINTENANCE NEVADA 750 i.e. 2.1.7. LOCATION OF CONTROLS / INSTRUMENTS Key: Clutch lever Ignition switch / steering lock ( Instruments and indicators Front brake lever Throttle twistgrip High beam flasher button ( Lights selector ( Choke lever ( Direction indicators switch ( 10.

  • Page 35: Maintenance Operations

    PERIODIC MAINTENANCE NEVADA 750 i.e. 2.2. MAINTENANCE OPERATIONS 2.2.1. ENGINE OIL AND FILTER CHANGE ENGINE OIL CHANGE IMPORTANT Oil flows more easily when warm. Let the engine warm up for about twenty minutes to facilitate total drainage. • Place a container of capacity greater than 4000 cm (244 in ) under the drain plug.

  • Page 36: Cleaning The Air Filter

    PERIODIC MAINTENANCE NEVADA 750 i.e. 2.2.2. CLEANING THE AIR FILTER • Working on either side, loosen and remove outer air conveyor screw. • Remove both outer air conveyors, pay attention to the fasteners. • Working on either side, loosen and remove inner air conveyor three screws.
  • Page 37 PERIODIC MAINTENANCE NEVADA 750 i.e. • Remove the ties from air breather hose. • Remove the airbox cover from the vehicle right-hand side. • Remove the air filter. 2 - 17...

  • Page 38: Systems Layout

    PERIODIC MAINTENANCE NEVADA 750 i.e. 2.3. SYSTEMS LAYOUT 2.3.1. SYSTEMS LAYOUT BRAKES SYSTEM Key: Front brake disc Front calliper. Front brake line. Front brake master cylinder with lever and reservoir. Rear brake lever Rear brake master cylinder Rear brake reservoir. Rear brake lines.
  • Page 39 PERIODIC MAINTENANCE NEVADA 750 i.e. 2 - 19...
  • Page 40 PERIODIC MAINTENANCE NEVADA 750 i.e. 2 - 20...
  • Page 41 PERIODIC MAINTENANCE NEVADA 750 i.e. EXHAUST SYSTEM 2 - 21...
  • Page 42 PERIODIC MAINTENANCE NEVADA 750 i.e. CRANKCASE OIL AND EXHAUST GAS RECOVERY SYSTEM 2 - 22...
  • Page 43 FUEL SYSTEM NEVADA 750 i.e. FUEL SYSTEM 3 - 1...
  • Page 44 FUEL SYSTEM NEVADA 750 i.e. SUMMARY 3.1. FUEL SYSTEM ..............................3 3.1.1. FUEL SYSTEM LAYOUT........................... 3 3.1.2. INJECTION SYSTEM LAYOUT......................... 4 3.1.3. CYLINDER SYNCHRONISATION......................6 3.1.4. SETTING THE CO RATE .......................... 8 3.1.5. AXONE 5.0.0 ............................. 9 3.1.6. INTAKE MANIFOLDS ..........................11 3 - 2...

  • Page 45: Fuel System

    FUEL SYSTEM NEVADA 750 i.e. 3.1. FUEL SYSTEM 3.1.1. FUEL SYSTEM LAYOUT Key: Fuel tank Throttle body Level check thermistor Fuel filter Fuel delivery line Fuel pump assembly 3 - 3...

  • Page 46: Injection System Layout

    FUEL SYSTEM NEVADA 750 i.e. 3.1.2. INJECTION SYSTEM LAYOUT 3 - 4...
  • Page 47 FUEL SYSTEM NEVADA 750 i.e. Key: Engine control unit Ignition switch Battery Fuel pump Coil Dashboard Air temperature sensor Throttle valve position sensor Injectors Crankshaft position sensor Engine temperature sensor Lambda sensor Bank angle sensor Side Stand 3 - 5...

  • Page 48: Cylinder Synchronisation

    FUEL SYSTEM NEVADA 750 i.e. 3.1.3. CYLINDER SYNCHRONISATION • With the vehicle engine switched off, connect the Axone 2000 instrument to the diagnostics connector and the vehicle battery. • Switch on the instrument. • Screw the unions for connection of the vacuum meter lines to the threaded bores on the intake pipes.
  • Page 49 FUEL SYSTEM NEVADA 750 i.e. • Bring the engine to just above idle speed: 2000 – 3000 rpm. • Check cylinder balancing on the vacuum meter. • Balance the cylinders by turning throttle bodies control rod adjuster, on vehicle left-hand side, until cylinders are balanced.

  • Page 50: Setting The Co Rate

    FUEL SYSTEM NEVADA 750 i.e. 3.1.4. SETTING THE CO RATE The CO setting (injectors opening time) cannot be adjusted; the only facility is that of resetting the self-adaptive parameters in the event of replacement of the throttle body due to wear. 3 - 8...

  • Page 51: Axone 5.0.0

    FUEL SYSTEM NEVADA 750 i.e. 3.1.5. AXONE 5.0.0 ICON DISPLAY ENGINE PARAMETER READING DEVICE STATUS (generally on/off) DEVICE ACTIVATION ERRORS DISPLAY ADJUSTABLE PARAMETERS DISPLAY DESCRIPTION Throttle potentiometer Trimmer TPS Exact throttle position Lambda sensor Lambda integr. Partial charge autoad. Idle control self-adj Mult.
  • Page 52 FUEL SYSTEM NEVADA 750 i.e. Engine temperature Left coil Right coil Left Injector Right Injector Lambda sensor Air temperature Throttle ERRORS DISPLAY Pressur Battery voltage Fuel pump relay Autoadapt.parameters RAM Memory ROM Memory EEPROM Microprocessor Signal panel Throttle pos.self-teac ADJUSTABLE PARAMETERS Selfadapt.param.reset 3 - 10...

  • Page 53: Intake Manifolds

    FUEL SYSTEM NEVADA 750 i.e. 3.1.6. INTAKE MANIFOLDS • When fitting intake manifolds (1-2) tighten screws (3) simultaneously. 3 - 11...
  • Page 54 ENGINE NEVADA 750 i.e. ENGINE 4 - 1...
  • Page 55 ENGINE NEVADA 750 i.e. SUMMARY 4.1. DROPPING AND REFITTING THE ENGINE....................3 4.1.1. DROPPING THE ENGINE FROM THE FRAME..................3 4.1.2. REFITTING THE ENGINE IN THE FRAME..................... 11 4.1.3. TIGHTENING TORQUES ........................18 4 - 2...

  • Page 56: Dropping And Refitting The Engine

    ENGINE NEVADA 750 i.e. 4.1. DROPPING AND REFITTING THE ENGINE 4.1.1. DROPPING THE ENGINE FROM THE FRAME • drop engine block first remove superstructures, the battery, the exhaust tailpipes, the dampers and the rear wheel. • Disconnect the speed sensor and remove the cable from the harness.
  • Page 57 ENGINE NEVADA 750 i.e. • Remove the rpm sensor without disconnecting the wiring. • Remove the spindle, with cotter, responsible for securing the clutch linkage to the engine block, and then free the control cable. 4 - 4...
  • Page 58 ENGINE NEVADA 750 i.e. • Remove the injectors retainer and withdraw the injectors from their seat on the intake manifolds. • Disconnect the spark plug leads from the coils and separate them from the frame. 4 - 5...
  • Page 59 ENGINE NEVADA 750 i.e. • Loosen the clamps on the intake manifolds. • Detach the oil breather pipes on the cylinder heads. • Remove the engine temperature sensor connection. • Disconnect the starter motor and the lambda sensor. 4 - 6...
  • Page 60 ENGINE NEVADA 750 i.e. • Open the clamp and detach the airbox oil breather tube. • Disconnect the neutral indicator. 4 - 7...
  • Page 61 ENGINE NEVADA 750 i.e. • Disconnect the sidestand safety switch connector and separate the wiring from the frame. • Unscrew the screw that secures the earth lead lug to the engine block. • Support the bike frame on a motorcycle lift. •...
  • Page 62 ENGINE NEVADA 750 i.e. • Remove the upper screws joining the frame and the gearbox cover. • Remove the tie rod between the frame and gearbox. • Proceed to drop the engine: during the procedure check that the throttle body hoses detach properly from the intake manifolds without sustaining damage.
  • Page 63 ENGINE NEVADA 750 i.e. • Lower the engine checking that it separates correctly from the frame. • During the operation detach the oil pressure transmitter connection. 4 - 10...

  • Page 64: Refitting The Engine In The Frame

    ENGINE NEVADA 750 i.e. 4.1.2. REFITTING THE ENGINE IN THE FRAME • With the motorcycle frame secured on a lift, jack up the engine into position. • During this procedure reconnect the oil pressure transmitter and check that the throttle body hoses engage correctly over the intake manifolds.
  • Page 65 ENGINE NEVADA 750 i.e. • Secure the frame front arms to the engine cradle by means of the four Allen screws and torque the screws to the prescribed value. • Fit the screw responsible for securing the earth lead lug to the engine block. •...
  • Page 66 ENGINE NEVADA 750 i.e. • Insert the oil breather pipe into the airbox and secure it with the specific clamp. • Connect the starter motor and the lambda sensor. 4 - 13...
  • Page 67 ENGINE NEVADA 750 i.e. • Reconnect the engine temperature sensor. • Fit the breather pipes in the cylinder heads and secure them with the specific clamps. • Tighten the clamps on the intake manifolds. 4 - 14...
  • Page 68 ENGINE NEVADA 750 i.e. • Fit the injectors into their seats and assemble the retainer, tightening the screw to the prescribed torque value. • Connect the spark plug leads to the ignition coils. • Position the clutch linkage and fit the spindle to the engine block, fixing with the relative cotter.
  • Page 69 ENGINE NEVADA 750 i.e. • Refit the swing arm complete with bevel gear set. • Fit the rpm sensor and torque the screws to the prescribed value. 4 - 16...
  • Page 70 ENGINE NEVADA 750 i.e. • Remake the alternator electrical connections. • Reconnect the vehicle speed sensor. 4 - 17...

  • Page 71: Tightening Torques

    ENGINE NEVADA 750 i.e. 4.1.3. TIGHTENING TORQUES ENGINE CONNECTING PARTS Front tie rod nut 45 Nm Nut for long and short screws 45 Nm Clutch housing cover to engine fixing screws 25 Nm 4 - 18...
  • Page 72 ELECTRICAL SYSTEM NEVADA 750 i.e. ELECTRICAL SYSTEM 5 - 1...
  • Page 73 ELECTRICAL SYSTEM NEVADA 750 i.e. SUMMARY 5.1.1. COMPONENTS CHECK..........................3 5.1.2. ECU CONNECTIONS..........................10 5.1.3. WIRING DIAGRAM..........................11 5 - 2...
  • Page 74 ELECTRICAL SYSTEM NEVADA 750 i.e. 5.1.1. COMPONENTS CHECK 5 - 3...
  • Page 75 ELECTRICAL SYSTEM NEVADA 750 i.e. DASHBOARD DASHBOARD PINOUT Pin Designation Signal type Right turn signal switch Digital input Vehicle speed sensor power Power output supply Right turn signal switch Digital input Dashboard power supply (+15) Power input Engine speed signal Frequency input Fuel level sensor signal Analog input...
  • Page 76 ELECTRICAL SYSTEM NEVADA 750 i.e. FUEL PUMP Fuel pump power draw 4A (with power supply of 12V measured across pins 1 and 2) Fuel level sensor: resistance 1.4KΩ (measured across pins 3 and 4 with fuel level 0 litres) THROTTLE POTENTIOMETER (TPS) resistance 1290 Ω...
  • Page 77 ELECTRICAL SYSTEM NEVADA 750 i.e. TAIL-LIGHT rear parking light/brake light: 12V – 5/21 W number plate light 12V – 5 W BATTERY 12 V – 14 Ampere/hour MAIN FUSES F – From battery to voltage regulator (30 A). G – From battery to ignition key and fuses C and D (30 A). IMPORTANT One spare fuse is supplied.
  • Page 78 ELECTRICAL SYSTEM NEVADA 750 i.e. SPEED SENSOR hall effect sensor with 6 pulse/revolution square wave output INTAKE AIR TEMPERATURE SENSOR NTC type sensor resistance 3.7 KΩ (temperature 20°C – 68°F) ENGINE SPEED SENSOR inductive type sensor winding resistance 650 Ω (measured across pins 1 and 2) output voltage 0-5 V (measured during drive) CYLINDER HEAD TEMPERATURE SENSOR NTC type sensor...
  • Page 79 ELECTRICAL SYSTEM NEVADA 750 i.e. SECONDARY FUSES A – From ignition key to safety logic / starting (15 A). B – From ignition key to lights, brake lights, horn, turn signals (15 A). C – From battery to injection permanent power supply (3 A). D –...
  • Page 80 ELECTRICAL SYSTEM NEVADA 750 i.e. ENGINE OIL PRESSURE SENSOR normally open contact ALTERNATOR 12 V 330 N single phase alternator winding resistance 0.2-0.3 Ω output voltage 20 V AC (measured with alternator disconnected from electrical system and engine idling) output voltage 65 V AC (measured with alternator disconnected from electrical system and engine at 4000 rpm) HEADLIGHT...
  • Page 81 ELECTRICAL SYSTEM NEVADA 750 i.e. 5.1.2. ECU CONNECTIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 ECU SIDE DESIGNATION SIGNAL TYPE Throttle position sensor power supply Power output Lambda sensor signal (ground) Analog input...
  • Page 82 ELECTRICAL SYSTEM NEVADA 750 i.e. 5.1.3. WIRING DIAGRAM 5 - 11...
  • Page 83 ELECTRICAL SYSTEM NEVADA 750 i.e. Key: WIRE COLOURS: Multiple connectors Orange RPM sensor Light blue Oil pressure sensor Blue Left coil White Right coil Yellow Spark plugs Grey Left injector Brown Right injector Black Fuel pump Low fuel sensor Green Main inj.
  • Page 84 TRANSMISSION NEVADA 750 i.e. TRANSMISSION 6 - 1...
  • Page 85 TRANSMISSION NEVADA 750 i.e. SUMMARY 6.1. SWING ARM COMPLETE WITH TRANSMISSION ASSY ................3 6.1.1. REMOVAL ..............................3 6.1.2. INSPECTION .............................. 8 6.1.3. REASSEMBLY............................9 6.1.4. TIGHTENING TORQUES ......................... 12 6.2. TRANSMISSION CASE..........................13 6.2.1. REMOVING THE PINION HOUSING ....................... 13 6.2.2.

  • Page 86: Swing Arm Complete With Transmission Assy

    TRANSMISSION NEVADA 750 i.e. 6.1. SWING ARM COMPLETE WITH TRANSMISSION ASSY 6.1.1. REMOVAL • Remove the left silencer. • Remove the rear brake caliper, release the brake line from the swingarm fastener. • Loosen and remove the brake caliper holder screw. 6 - 3...
  • Page 87 TRANSMISSION NEVADA 750 i.e. • Remove both rear suspensions. • Loosen and remove the nut, collect the washer. • Loosen the screw securing the wheel shaft. • Remove the wheel shaft, collect the spacer. 6 - 4...
  • Page 88 TRANSMISSION NEVADA 750 i.e. • Remove the rear wheel. • Loosen the tie. • Remove the protection. • Loosen the nuts. • Loosen the shafts so that the swingarm can be detached from the gearbox. 6 - 5...
  • Page 89 TRANSMISSION NEVADA 750 i.e. • Remove the shim between swingarm right section and gearbox. • Unscrew the four nuts and recover the washers. • Remove the complete transmission case from the swing arm. • Remove the sleeve from the pinion. •...
  • Page 90 TRANSMISSION NEVADA 750 i.e. • Withdraw the gear. 6 - 7...

  • Page 91: Inspection

    TRANSMISSION NEVADA 750 i.e. 6.1.2. INSPECTION • Check that the cardan coupling is in good condition, that the gear teeth that mesh with the sleeve splines and the coupling splines are not damaged or excessively worn; otherwise, renew the coupling. •...

  • Page 92: Reassembly

    TRANSMISSION NEVADA 750 i.e. 6.1.3. REASSEMBLY • Equip the transmission case bevel pinion with the sleeve and cap • Fit the transmission case studs correctly into the corresponding holes in the swing arm. • Snug the nuts complete with washers without tightening.
  • Page 93 TRANSMISSION NEVADA 750 i.e. • Fit the spacer and wheel axle and tighten the nuts fully working in crosswise sequence. • Fit the dust cover with internal circlip in the front of the swing arm. • Fit the spring in the relative bore in the cardan coupling and apply grease to hold it in position.
  • Page 94 TRANSMISSION NEVADA 750 i.e. • Fit the nuts onto the studs and tighten them fully down. • Tighten the jubilee clamp. • Fit the rear wheel. 6 - 11...

  • Page 95: Tightening Torques

    TRANSMISSION NEVADA 750 i.e. 6.1.4. TIGHTENING TORQUES ENGINE CONNECTING PARTS Front tie rod nut 45 Nm Nut for long and short screws 45 Nm Clutch housing cover to engine fixing screws 25 Nm 6 - 12...

  • Page 96: Transmission Case

    TRANSMISSION NEVADA 750 i.e. 6.2. TRANSMISSION CASE 6.2.1. REMOVING THE PINION HOUSING • Remove the swing arm case. • Withdraw the complete pinion housing from the transmission case. • Clamp the bevel gear set holder tool (19907100) in a vice. •...
  • Page 97 TRANSMISSION NEVADA 750 i.e. • Remove the distance collar. • Remove the pinion. • Remove the clearance washer. • Remove the O-ring. • Remove the oil seal. • Remove the taper roller bearing from the housing. • Remove the O-ring. •...
  • Page 98 TRANSMISSION NEVADA 750 i.e. • Remove the taper roller bearing from the housing. 6 - 15...

  • Page 99: Inspection

    TRANSMISSION NEVADA 750 i.e. 6.2.2. INSPECTION • Check that the pinion teeth are in good condition, not excessively worn and undamaged; if necessary renew the bevel gear set. • Check that the two taper roller bearings are in good condition, that the rollers are undamaged and not excessively worn;...

  • Page 100: Reassembly

    TRANSMISSION NEVADA 750 i.e. 6.2.3. REASSEMBLY • If you need to renew the bevel pinion then you must also renew bevel gear mounted transmission case. The pinion and gear in the set must be stamped with the same identification number. •...
  • Page 101 TRANSMISSION NEVADA 750 i.e. • Use the specific punch (19926200) to fit the bearing inner race to the pinion. • Equip the pinion with the two clearance washers • Equip the pinion with the distance collar • Fit the O-ring. •...
  • Page 102 TRANSMISSION NEVADA 750 i.e. • Fit the distance collar. • Insert the splined shaft of the pinion in the special tool (19907100) and tighten the nut. 6 - 19...

  • Page 103: Tightening Torques

    TRANSMISSION NEVADA 750 i.e. 6.2.4. TIGHTENING TORQUES REAR TRANSMISSION Bevel pinion to case fixing nut 100 Nm Bevel gear to hollow shaft fixing screws 42 Nm Cover to transmission case fixing screws 25 Nm 6 - 20...

  • Page 104: Disassembling The Transmission Case

    TRANSMISSION NEVADA 750 i.e. 6.3. DISASSEMBLING THE TRANSMISSION CASE 6.3.1. DISASSEMBLING THE TRANSMISSION CASE • Unscrew the screws and set the washers aside. • Remove the brake disk from the hollow shaft. • Unscrew the screws and set aside the square washers and spring washers.
  • Page 105 TRANSMISSION NEVADA 750 i.e. Remove the following parts from the cover: • The roller bearing. • Use the specific punch (19907000) to drive out the taper roller bearing inner race. • Remove the washer. • Remove the washer. • Unscrew the screws and set the locking tabs aside; •...
  • Page 106 TRANSMISSION NEVADA 750 i.e. • Remove the seal ring. • Use the specific punch to drive the bearing out of the cover. • Use the specific puller (19927500) to remove the taper roller bearing outer race from the transmission case. •...

  • Page 107: Inspection

    TRANSMISSION NEVADA 750 i.e. 6.3.2. INSPECTION • Check that the fins of the hollow shaft subject to the action of the torque dampers are not damaged; check that the contact surfaces of: the seal ring, the bearing on the cover, the outer race of the bearing on the transmission case, the circlip groove on the hollow shaft: are not excessively worn, damaged, or pitted, otherwise renew the parts.

  • Page 108: Pinion - Gear Meshing (Bevel Gear Set)

    TRANSMISSION NEVADA 750 i.e. 6.3.3. PINION – GEAR MESHING (BEVEL GEAR SET) Perform these operations to mesh the pinion and gear: • Use two nuts and suitable spacers to temporarily secure the housing complete with pinion to the transmission case; •...
  • Page 109 TRANSMISSION NEVADA 750 i.e. • Fit the gear-hollow shaft assy., cover and relative spacers and gaskets to the transmission case and temporarily screw down the fixing screws. • Equip the gear holder hollow shaft with a Universal puller tool having central spacers in such a way as to maintain the gear so that it exerts slight pressure towards the brake disk side.
  • Page 110 TRANSMISSION NEVADA 750 i.e. • If the contact markings are as shown here, the pinion is too close to the gear axis of rotation: move the pinion backwards by reducing the thickness of the shim • If the contact markings are as shown here, the pinion is too far from the gear axis of rotation: move the pinion forwards by increasing the thickness of the shim.

  • Page 111: Reassembly

    TRANSMISSION NEVADA 750 i.e. 6.3.4. REASSEMBLY • Fit the washer on the transmission case. • Use the specific punch (19926000) to fit the seal ring on the transmission case. • Use the specific punch (19926500) to fit the roller bearing outer race to the transmission case. 6 - 28...
  • Page 112 TRANSMISSION NEVADA 750 i.e. • Use the specific punch to fit the bearing to the cover. • Use the specific punch (19927900) to fit the roller bearing inner race to the hollow shaft; • Fit the seal ring to the hollow shaft.. •...
  • Page 113 TRANSMISSION NEVADA 750 i.e. • Insert the square locking tabs and tighten the screws. • Fit the washer. • Fit the washer. • Fit the circlip. • Fit the gaskets and spacer to the cover. • Tighten the screws complete with square locking tabs and washers.
  • Page 114 TRANSMISSION NEVADA 750 i.e. • Fit the brake disk to the hollow shaft and use a torque wrench to tighten the screws complete with washers. • When reassembling the bevel pinion housing to the transmission assy. take account of the fact that the oil flow channels with holes must be assembled in a vertical line (observing the channels, one must be facing upwards and the other facing downwards).

  • Page 115: Tightening Torques

    TRANSMISSION NEVADA 750 i.e. 6.3.5. TIGHTENING TORQUES REAR TRANSMISSION Bevel pinion to case fixing nut 100 Nm Bevel gear to hollow shaft fixing screws 42 Nm Cover to transmission case fixing screws 25 Nm 6 - 32...

  • Page 116: Rear Swing Arm

    TRANSMISSION NEVADA 750 i.e. 6.4. REAR SWING ARM 6.4.1. DISASSEMBLY • Remove the left silencer. • Remove the rear brake caliper, release the brake line from the swingarm fastener. • Loosen and remove the brake caliper holder screw. 6 - 33...
  • Page 117 TRANSMISSION NEVADA 750 i.e. • Remove both rear suspensions. • Loosen and remove the nut, collect the washer. • Loosen the screw securing the wheel shaft. • Remove the wheel shaft, collect the spacer. 6 - 34...
  • Page 118 TRANSMISSION NEVADA 750 i.e. • Remove the rear wheel. • Loosen the tie. • Remove the protection. • Loosen the nuts. • Loosen the shafts so that the swingarm can be detached from the gearbox. 6 - 35...
  • Page 119 TRANSMISSION NEVADA 750 i.e. • Remove the shim between swingarm right section and gearbox. 6 - 36...

  • Page 120: Inspection

    TRANSMISSION NEVADA 750 i.e. 6.4.2. INSPECTION • Check that the arms of the swing arm assy. show no signs of cracking or distortion; otherwise, if possible, true up the swing arm assy. observing the measurements shown in the drawing. 458 ± 0,1 18.031 ±...

  • Page 121: Reassembly

    TRANSMISSION NEVADA 750 i.e. 6.4.3. REASSEMBLY • Screw in the pin on the right-hand side until it protrudes from the swing arm sufficiently to hold the shim. • Insert the swing arm into the transmission case cover. • Tighten the left-hand pin fully down until the shim on the right-hand side is located against the bearing fitted to the transmission case cover.
  • Page 122 TRANSMISSION NEVADA 750 i.e. • Tighten the jubilee clamp. • Fit the rear wheel. 6 - 39...

  • Page 123: Tightening Torques

    TRANSMISSION NEVADA 750 i.e. 6.4.4. TIGHTENING TORQUES REAR SUSPENSION Rear suspension upper and lower sections fixing screws 20 Nm 6 - 40...
  • Page 124 CYCLE PARTS NEVADA 750 i.e. CYCLE PARTS 7 - 1...
  • Page 125 CYCLE PARTS NEVADA 750 i.e. SUMMARY 7.1. FRONT FORK ..............................3 7.1.1. DIAGRAM ..............................3 7.1.2. FORK LEG REMOVAL ..........................4 7.1.3. OVERHAUL ..............................7 7.1.4. TROUBLESHOOTING ..........................8 7.1.5. FRONT FORK OIL CHANGE........................9 7.1.6. DISASSEMBLY / OVERHAUL ........................13 7.1.7.

  • Page 126: Front Fork

    CYCLE PARTS NEVADA 750 i.e. 7.1. FRONT FORK 7.1.1. DIAGRAM Key: Screw 19. Fork base Washer 20. Ring nut Screw 21. Fork bridge Complete left-hand slider 22. Washer Upper Bushing 23. Nut 24. Rubber plug Seal ring 25. Spacer tube Stop ring 26.

  • Page 127: Fork Leg Removal

    CYCLE PARTS NEVADA 750 i.e. 7.1.2. FORK LEG REMOVAL The motorcycle is equipped with a non-adjustable fork. The procedures described below apply to both the fork legs. WARNING During the following procedures, the legs and their internal components must be clamped in a vice.
  • Page 128 CYCLE PARTS NEVADA 750 i.e. • Remove the instrument panel protection. • Loosen and remove the two screws, collect the washers. • Loosen and remove the nut under the instrument panel, collect the washer. • Move the instrument panel forward. 7 - 5...
  • Page 129 CYCLE PARTS NEVADA 750 i.e. • Unscrew the two lower clamping screws • Loosen the lower screw. • Slide out the fork leg downwards while rotating it first in one direction then in the opposite direction. 7 - 6...

  • Page 130: Overhaul

    CYCLE PARTS NEVADA 750 i.e. 7.1.3. OVERHAUL • Use new gaskets during reassembly after complete disassembly. • Use a non-inflammable and preferably biodegradable solvent for cleaning. • Lubricate all the contact surfaces before reassembly. • Always smear grease on the seal ring lips before reassembly.

  • Page 131: Troubleshooting

    CYCLE PARTS NEVADA 750 i.e. 7.1.4. TROUBLESHOOTING The following paragraph lists some potential problems with the fork and their causes complete with suggested solutions. Always refer to this table before working on the fork. PROBLEM CAUSE SOLUTION Oil leakage from the seal ring 1.

  • Page 132: Front Fork Oil Change

    CYCLE PARTS NEVADA 750 i.e. 7.1.5. FRONT FORK OIL CHANGE IMPORTANT The following procedures apply to both legs. The fork oil must be changed periodically, see (PERIODIC MAINTENANCE TABLE). IMPORTANT During oil drainage and filling operations, the fork leg and its internal parts must be clamped in a vice; take care to avoid damaging the parts by overtightening;...
  • Page 133 CYCLE PARTS NEVADA 750 i.e. • Drain the oil contents from the interior of the fork leg To facilitate the drainage of oil from inside the plunger rod, pump out the oil by repeatedly pushing the stanchion into the slider. •...
  • Page 134 CYCLE PARTS NEVADA 750 i.e. • Pump the stanchion up and down to ensure the plunger rod is completely filled with oil. • Insert the spring and pre-load tube. • Fit the plug on the stanchion tube taking care not to damage the O-ring.
  • Page 135 CYCLE PARTS NEVADA 750 i.e. • Tighten the plug to the prescribed torque. 7 - 12...

  • Page 136: Disassembly / Overhaul

    CYCLE PARTS NEVADA 750 i.e. 7.1.6. DISASSEMBLY / OVERHAUL • Drain all the oil from the fork leg. • Clamp the slider in a vice. • Unscrew the foot screw and remove it with the relative seal. • Remove the dust wiper seal by prising it with a screwdriver.
  • Page 137 CYCLE PARTS NEVADA 750 i.e. • Remove the stanchion tube from the slider together with the seal ring, the cap, the upper bushing and the lower bushing. IMPORTANT While removing the stanchion tube from the slider several parts may remain inside the slider, in which case they must be removed afterwards taking care not to damage the rim of the slider or the upper bushing seat on the slider...

  • Page 138: Inspection

    CYCLE PARTS NEVADA 750 i.e. 7.1.7. INSPECTION Check all the parts removed from inside the slider, • specifically: the seal ring and the dust wiper seal since these parts ensure the oiltight properties; these parts must be renewed if damaged; Check the bushing on the stanchion;...

  • Page 139: Reassembly

    CYCLE PARTS NEVADA 750 i.e. 7.1.8. REASSEMBLY WARNING Before reassembly all components must be carefully washed and dried with compressed air. • Perform all the necessary overhaul procedures • Insert the plunger assy. into the stanchion tube complete with counter-spring and ring. •...
  • Page 140 CYCLE PARTS NEVADA 750 i.e. • Slide the stanchion into the slider and push it fully home. • Screw in the foot screw with its seal and tighten it to the prescribed torque. • Place the retainer and the well-lubricated seal ring on the stanchion tube.
  • Page 141 CYCLE PARTS NEVADA 750 i.e. • Install the wiper seal. • Pour oil into the stanchion ensuring that it also fills the internal passages of the plunger rod. • Pump the stanchion up and down to ensure the plunger rod is completely filled with oil. •...

  • Page 142: Reassembly Of The Fork Leg

    CYCLE PARTS NEVADA 750 i.e. 7.1.9. REASSEMBLY OF THE FORK LEG • Fit the fork leg to the motorcycle, passing it through the lower plate and the upper plate. • Tighten the screws to the prescribed torque. 7 - 19...

  • Page 143: Tightening Torques

    CYCLE PARTS NEVADA 750 i.e. 7.1.10. TIGHTENING TORQUES FRONT SUSPENSION Centre stand to frame fixing screws Lock nut Fork head fixing screws Fork base fixing screws Slider to wheel spindle fixing screws 7 - 20...

  • Page 144: Adjusting Play In The Steering Bearings

    CYCLE PARTS NEVADA 750 i.e. 7.2. ADJUSTING PLAY IN THE STEERING BEARINGS 7.2.1. ADJUSTING PLAY IN THE STEERING BEARINGS • Remove the handlebars • Remove the dashboard • Working on both sides, unscrew and remove the screw that secures the top plate to the front forks •...
  • Page 145 CYCLE PARTS NEVADA 750 i.e. • Remove the top plate from the front fork • Adjust the ringnut • Position the top plate on the front fork • Tighten the central nut • Working on both sides unscrew and remove the screw that secures the top plate to the front forks •...

  • Page 146: Tightening Torques

    CYCLE PARTS NEVADA 750 i.e. 7.2.2. TIGHTENING TORQUES STEERING Steering head fixing screw 50 Nm 7 - 23...

  • Page 147: Rear Suspensions

    CYCLE PARTS NEVADA 750 i.e. 7.3. REAR SUSPENSIONS 7.3.1. REMOVING THE REAR SUSPENSION • Loosen the screws securing the suspension guards to the frame. • Remove the suspension guards. 7 - 24...
  • Page 148 CYCLE PARTS NEVADA 750 i.e. • Loosen the suspension lower screw. • Remove the suspensions from the shafts. 7 - 25...

  • Page 149: Inspection

    CYCLE PARTS NEVADA 750 i.e. 7.3.2. INSPECTION • Check the condition of the springs and the dampers (always inspect in pairs in order to ensure they present identical preload to avoid unequal forces being exerted on the rear swing arm and the transmission case); if necessary, renew either the springs or the complete suspension struts.

  • Page 150: Refitting The Rear Suspension

    CYCLE PARTS NEVADA 750 i.e. 7.3.3. REFITTING THE REAR SUSPENSION • Position the suspension to shafts. • Tighten the rear suspension lower screw. • Refit the suspension guards. • Tighten the screws securing the suspension guards to the frame. 7 - 27...
  • Page 151 CYCLE PARTS NEVADA 750 i.e. 7 - 28...

  • Page 152: Tightening Torques

    CYCLE PARTS NEVADA 750 i.e. 7.3.4. TIGHTENING TORQUES REAR SUSPENSION Rear suspension upper and lower sections fixing screws 20 Nm 7 - 29...
  • Page 153 Moto Guzzi S.p.a. Via E.V. Parodi, 57 23826 Mandello del Lario (LECCO) Italy Tel. +39 0341 709111 Fax +39 0341 709220 www.motoguzzi.it www.servicemotoguzzi.com...

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