Page 1 SERVICE STATION MANUAL 854310 BREVA V1100 - ABS...
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 V1100 - ABS 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 V1100 - ABS 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 V1100 - ABS Characteristics This number is composed by numbers and letters, as in the example shown below. ZGULPA000YMXXXXXX KEY: ZGU: WMI (World manufacture identifier) code; LP: model; A00: version variation; 0: digit free Y year of manufacture M: production plant (M= Mandello del Lario); XXXXXX: progressive number (6 digits);...
Page 12 BREVA V1100 - ABS 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 V1100 - ABS Characteristics Specification Desc./Quantity High-beam light 12 V - 65 W H9 Turn indicators 12V - 10 W (orange bulb) 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...
Page 14: Wheels And Tyres
BREVA V1100 - ABS 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 DUNLOP D220 ST Sportmax Front 120/70 - ZR 17"...
Page 15 BREVA V1100 - ABS Characteristics Name Torque in Nm Oil intake filter fixing screw - TCEI M6x16 (1) 10 Nm (7.38 lbf ft) - Loctite 648 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)
Page 16 BREVA V1100 - ABS Characteristics Name Torque in Nm Coil retainer 2 Nm Engine retainer 80 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 6 Nm...
Page 17 BREVA V1100 - ABS Characteristics Name Torque in Nm Silencer to support retainer (screw +nut) 25 Nm 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...
Page 18 BREVA V1100 - ABS Characteristics Name Torque in Nm Lug to engine retainer 25 Nm Right to left lug retainer 4 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...
Page 19: Piston Rings
BREVA V1100 - ABS 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. Fitting backlash detected between the ring thickness and seats on the piston: Sealing rings and oil scraper 0.030 - 0.065 mm (0.00118 - 0.00256 in) Gap between the end of the piston rings inserted in the cylinder:...
Page 20 BREVA V1100 - ABS Characteristics Specification Desc./Quantity fitting clearance 0.025 - 0.066 mm (0.00098 ÷ 0.00260 inch) CAMSHAFT (CAM) SUPPORT DIAMETER AND THEIR SEATS ON THE CRANKCASE (FLYWHEEL SIDE) Specification Desc./Quantity Shaft support diameter 32.000 - 31.984 mm (1.25984 ÷ 1.25921 inch) Seat diameter on base 32.025 - 32.050 mm (1.26082 ÷...
Page 21: Index Of Topics
INDEX OF TOPICS S-TOOLS PECIAL TOOLS...
Page 22: Special Tools
BREVA V1100 - ABS 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 05.90.19.30 Inner spark plug removal 05.92.80.30 Piston ring clamp 05.92.72.30 Timing system cover sealing ring punch S-TOOLS - 22...
Page 23 BREVA V1100 - ABS Special tools Stores code Description 01.92.91.00 Wrench for removing the cover on sump and filter 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...
Page 24 BREVA V1100 - ABS Special tools Stores code Description 30.90.65.10 Tool for clutch fitting 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...
Page 25 BREVA V1100 - ABS Special tools Stores code Description 000019663300 Tool for clutch shaft removal 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 S-TOOLS - 25...
Page 26 BREVA V1100 - ABS Special tools Stores code Description 05.90.27.35 Pinion oil seal buffer 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 V1100 - ABS 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 BEFORE EACH RIDE AND EVERY 2000 (1250 Action...
Page 29: Transmission Fluid
BREVA V1100 - ABS 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 Air filter - Check and clean, adjust, grease or replace if necessary Engine oil filter - Replace General vehicle operation - Check and clean, adjust, grease or replace if necessary.
Page 30 BREVA V1100 - ABS 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...
Page 31 BREVA V1100 - ABS 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 V1100 - ABS 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. NOTE NEVER REUSE AN OLD FILTER.
Page 33: Air Filter
BREVA V1100 - ABS 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. Replacement NOTE HOT OIL IS MORE FLUID AND WILL DRAIN OUT MORE EASILY AND COMPLETELY.
Page 34: Checking The Valve Clearance
BREVA V1100 - ABS 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 V1100 - ABS 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 V1100 - ABS 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: MIN = minimum level MAX = maximum level If the fluid does not reach at least the "MIN"...
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 V1100 - ABS Electrical system Components arrangement Key: 1 Coil 2 Instrument panel 3 Fuel pump 4 Injector ELE SYS - 39...
Page 40: Electrical System Installation
BREVA V1100 - ABS 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 16 Instrument panel air temperature sensor 17 Front headlamp...
Page 41: General Wiring Diagram
BREVA V1100 - ABS Electrical system General wiring diagram Key: 1. Multiple connectors 2. Clutch switch ELE SYS - 41...
Page 42 BREVA V1100 - ABS Electrical system 3. Start-up relay 4. Light relay 5. Right light switch 6. HAZARD button lighting LED 7. HAZARD button 8. Horn 9. Left light switch 10.Instrument panel air temperature thermistor 11.Instrument panel 12.Key switch 13.Immobilizer aerial 14.Heated handgrips 15.Heated handgrip control 16.Right rear turn indicator...
Page 43 BREVA V1100 - ABS Electrical system 41.Right cylinder inner spark plug 42.Right cylinder outer spark plug 43.Left cylinder inner spark plug 44.Left cylinder outer spark plug 45.Right cylinder double coil 46.Left cylinder double coil 47.Right injector 48.Left injector 49.ABS switch 50.Fall sensor 51.Flywheel pick up 52.Pick-up wire shielding...
Page 44: Enter New Code
BREVA V1100 - ABS Electrical system V green Vi purple Checks and inspections 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 V1100 - ABS Electrical system Throttle Valve Error DC Gnd ECU 11 Engine Temperature Error DC V DC ECU 14 Engine Temperature Error DC Gnd ECU 15 Air Temperature Error DC V DC ECU 16 Air Temperature Error DC Gnd ECU 17 Low Battery Error ECU 20 Lambda Probe Error ECU 21 Coil 1 Error DC V DC ECU 22...
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 V1100 - ABS Electrical system Battery recharge circuit 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 2 with 12V voltage) Fuel level sensor:...
Page 48: Front Headlamp
BREVA V1100 - ABS 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 lighting, relay coil lights (15 A).
Page 49: Main Fuses
BREVA V1100 - ABS 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. ABS FUSES 3 - ABS pump (40 A). 4 - ABS solenoid valves (25 A).
Page 50 BREVA V1100 - ABS Electrical system 17 Stepper motor (+) 18 Stepper motor (-) 19 Stepper motor (-) 20 5V power supply (NTC sensors) 21 Not used 22 Not used 23 Neutral sensor signal 24 Not used 25 Engine revolution sensor signal 26 Not used 27 Not used 28 Left cylinder injector control...
Page 51 BREVA V1100 - ABS Electrical system 15 Not used 16 K line (diagnosis) 17 Power supply from main relay 18 Not used 19 Not used 20 CAN - H line (ccm/instrument panel) 21 Not used 22 Oxygen probe signal 23 Not used 24 Vehicle speed signal input 25 Not used 26 Not used...
Page 52: Front Speed Sensor
BREVA V1100 - ABS Electrical system 13 Not used 14 ABS deactivation switch 15 Not used 16 Front (ABS) speed sensor (signal / earth con- nection) 17 Not used 18 Switch 19 Rear (ABS) speed sensor (signal / earth con- nection) 20 Not used 21 Not used...
Page 53: Engine Rpm Sensor
BREVA V1100 - ABS Electrical system REAR SPEED SENSOR It is used exclusively by the ABS module. Differential Hall effect sensor. 2-pin connector (Supply / Signal-Earth connec- tion). Engine rpm sensor Measures the engine revolution speed and each cylinder timing in relation to the TDC Inductive type sensor, with three-way connector: •...
Page 54: Engine Temperature Sensor
BREVA V1100 - ABS Electrical system Engine temperature sensor This sensor, 5V powered, features NTC specifica- tions and sends the control unit a signal which varies depending on temperature to help manage the stoichiometric ratios during engine speed ad- justment. NGINE TEMPERATURE SENSOR RESISTANCE Specification Desc./Quantity...
Page 55: Lambda Sensor
BREVA V1100 - ABS Electrical system Lambda sensor Oxygen sensor with heater. Sensor voltage between 0 and 0.9 V (to be meas- ured between pins 1 and 2). Heater resistance 12.8 Ohm (to be measured be- tween pins 3 and 4 at 20°C - 68°F). Injector Resistance 14 Ohm ±...
Page 56: Engine Oil Pressure Sensor
BREVA V1100 - ABS Electrical system Engine oil pressure sensor There is a failure in the oil pressure sensor when it is detected as not conducting (open) with the en- gine off and the key set to ON. This problem is signalled by the lighting of the "service"...
Page 57: Heated Handgrip Control
BREVA V1100 - ABS Electrical system Dashboard PIN USE 1 + KEY 2 RIGHT TURN INDICATOR CONTROL 3 OIL PRESSURE SENSOR 4 HIGH-BEAM LIGHT INPUT 6 SELECT 1 7 SELECT 2 8 FUEL LEVEL SENSOR 9 AIR TEMPERATURE SENSOR 10 - 11 + BATTERY 12 LEFT TURN INDICATOR CONTROL 13 -...
Page 58 BREVA V1100 - ABS Electrical system 35 RIGHT FRONT TURN INDICATOR ACTIVA- TION 36 LEFT REAR TURN INDICATOR ACTIVATION 37 LEFT FRONT TURN INDICATOR ACTIVA- TION 38 LEFT HEATED HANDGRIP ACTIVATION 39 RIGHT HEATED HANDGRIP ACTIVATION 40 AERIAL 2 ELE SYS - 58...
Page 59: Index Of Topics
INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 60: Removing The Engine From The Vehicle
BREVA V1100 - ABS 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 61 BREVA V1100 - ABS Engine from vehicle • Disconnect the idle motor connector. • Disconnect the engine temperature sensor connector. • Disconnect the throttle valve position sensor connector. ENG VE - 61...
Page 62 BREVA V1100 - ABS Engine from vehicle • Disconnect the revolution sensor con- nector. • Disconnect the alternator connector. • Disconnect the neutral sensor connec- tor. ENG VE - 62...
Page 63 BREVA V1100 - ABS 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 - 63...
Page 64 BREVA V1100 - ABS 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 65 BREVA V1100 - ABS Engine from vehicle • Unscrew and remove the radiator up- per fixing column. • Unscrew and remove the lower pin nut and collect the washer. • Remove the lower pin and collect the washer. • Remove the centre stand. ENG VE - 65...
Page 66 BREVA V1100 - ABS Engine from vehicle • Loosen the clamp. • Unscrew and remove the screws and collect the washers. • Remove the exhaust manifolds. • Remove the catalytic converter. ENG VE - 66...
Page 67 BREVA V1100 - ABS Engine from vehicle • Place the engine service stand. • Operating from both sides, unscrew and remove the front fixing screw. • Remove the clamps from the cable harness. • Unscrew and remove the two screws fixing the oil vapour union tube.
Page 68 BREVA V1100 - ABS Engine from vehicle • Partially lower the engine. • Disconnect the oil pressure sensor connector. • Lower the engine completely. Installing the engine to the vehicle • Fasten the vehicle chassis to a hoister and lift the engine to place it in its po- sition.
Page 69 BREVA V1100 - ABS Engine from vehicle • Fit the oil vapour union tube. • Tighten the two screws. • Operating from both sides, tighten the front fixing screw. • Fit the catalytic converter. • Fit the exhaust manifolds. ENG VE - 69...
Page 70 BREVA V1100 - ABS Engine from vehicle • Fit the washers and tighten the nuts. • Tighten the clamp. • Fit the centre stand. • Insert the lower pin and its washer. ENG VE - 70...
Page 71 BREVA V1100 - ABS Engine from vehicle • Fit the washer and tighten the engine lower fixing nut to the specified torque. • Fit the oil radiator. • Screw the upper fixing column. • Connect the horn connectors. • Fasten the clutch oil pipe with the screw and its washers.
Page 72 BREVA V1100 - ABS Engine from vehicle • Fit the clutch bleed pipe. • Fill up the clutch system. • Connect the Lambda probe connector. • Fit the starter motor connector. • Screw the nut and place the rubber cover. •...
Page 73 BREVA V1100 - ABS Engine from vehicle • Tighten the screw. • Fit the starter motor protection. • Tighten the two screws. • Connect the neutral sensor connector. • Connect the alternator connectors. ENG VE - 73...
Page 74 BREVA V1100 - ABS Engine from vehicle • Connect the revolution sensor connec- tor. • Connect the throttle valve position sen- sor connector. • Connect the engine temperature sen- sor connector. ENG VE - 74...
Page 75 BREVA V1100 - ABS Engine from vehicle • Connect the idle motor connector. • Correctly fit the throttle cables, adjust- ing clearance. • Connect the injector connectors. ENG VE - 75...
Page 76 BREVA V1100 - ABS Engine from vehicle • Connect the four spark plug tubes. • Refit the entire fork, reaction rod, con- necting rod assembly, brake calliper and the rear wheel. ENG VE - 76...
Page 77: Index Of Topics
INDEX OF TOPICS NGINE...
Page 78 BREVA V1100 - ABS Engine Gearbox Diagram KEY: 1. Ball bearing 2. Circlip ENG - 78...
Page 79 BREVA V1100 - ABS 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 80 BREVA V1100 - ABS 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 81: Removing The Gearbox
BREVA V1100 - ABS 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 82: Gearbox Shafts
BREVA V1100 - ABS 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 - 82...
Page 83 BREVA V1100 - ABS 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 84 BREVA V1100 - ABS 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 85 BREVA V1100 - ABS 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. ENG - 85...
Page 86 BREVA V1100 - ABS 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 87 BREVA V1100 - ABS 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 - 87...
Page 88 BREVA V1100 - ABS 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 89 BREVA V1100 - ABS 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 90 BREVA V1100 - ABS 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 - 90...
Page 91 BREVA V1100 - ABS 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 92 BREVA V1100 - ABS 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 Disassembling the gearbox Disassembling the clutch shaft...
Page 93 BREVA V1100 - ABS Engine VEHICLES WITH CHASSIS NUMBER FROM ZGULPA0026M111355 TO ZGULPA0006M111693 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 Checking the primary shaft Measure coaxiality of the main shaft with a dial gauge and a centring device and replace it if not...
Page 94: Checking The Secondary Shaft
BREVA V1100 - ABS 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 95: Assembling The Gearbox
BREVA V1100 - ABS 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. REMEMBER TO REPLACE ALL SEALING RINGS, CIRCLIPS AND SAFETY RINGS PREVIOUSLY REMOVED.
Page 96: Removing The Flywheel
BREVA V1100 - ABS 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. Specific tooling 12.91.18.01 Tool to lock the flywheel and the starting ring gear...
Page 97: Installing The Flywheel
BREVA V1100 - ABS 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 98 BREVA V1100 - ABS Engine • Remove the cover. • Unscrew and remove the eight screws. • Undo and remove the two screws. • Unscrew the nut and collect the screw. ENG - 98...
Page 99 BREVA V1100 - ABS 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 - 99...
Page 100: Tensioning The Belt
BREVA V1100 - ABS 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. Tensioning the belt •...
Page 101: Installing The Generator
BREVA V1100 - ABS 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 prescribed torque.
Page 102 BREVA V1100 - ABS 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 103 BREVA V1100 - ABS 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 104: Removing The Starter Motor
BREVA V1100 - ABS 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 105: Disassembling The Clutch
BREVA V1100 - ABS 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 starting ring gear...
Page 106 BREVA V1100 - ABS 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 - 106...
Page 107: Checking The Clutch Plates
BREVA V1100 - ABS 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. Crown gear for start-up Check that the supporting surface with the driven plate is perfectly smooth and even.
Page 108: Assembling The Clutch
BREVA V1100 - ABS 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 109 BREVA V1100 - ABS 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 110: Removing The Head Cover
BREVA V1100 - ABS 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 111: Removing The Cylinder Head
BREVA V1100 - ABS 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 112 BREVA V1100 - ABS Engine • Unscrew and remove the joint of the pipe that delivers oil to the head and collect the washer. • Using the suitable special tool, un- screw and remove the inner spark plug. Specific tooling 05.90.19.30 Inner spark plug removal •...
Page 113: Cylinder Head
BREVA V1100 - ABS Engine • Slightly detach the cylinder head and remove the four O-rings. • 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.
Page 114: Removing The Valves
BREVA V1100 - ABS Engine • Remove the rocking lever shafts. • 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 115: Checking The Valve Guides
BREVA V1100 - ABS Engine slid off the valve seats; unscrew the tool and remove it from the head. • Remove the upper retainer (2). • Remove the internal spring (3). • Remove the external spring (4). • Remove the lower retainer (5) and the shimming washers if necessary.
Page 116: Checking The Cylinder Head
BREVA V1100 - ABS Engine VALVE AND GUIDES COUPLING DATA CHART (OUTLET) Specification Desc./Quantity Valve guide inside diameter 8.005 ÷ 8.022 (0.3152 ÷ mm (in) 0.3158) Valve stem diameter mm (in) 7.965 ÷ 7.980 (0.3136 ÷ 0.3142) Fitting clearance mm (in) 0.025 ÷...
Page 117: Specific Tooling
BREVA V1100 - ABS Engine • Place the valve (6) inside the head. • Place the lower retainer (5) and the shimming washers. • Place the external spring (4). • Place the internal spring (3). • Insert the upper retainer (2). •...
Page 118 BREVA V1100 - ABS Engine 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. CAUTION THE NEW LUBRICATION SYSTEM IS VALID FROM EN- GINE NUMBER N°...
Page 119 BREVA V1100 - ABS Engine • Place the six washers and install the rocking levers. • Insert the rocking lever shafts. • 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...
Page 120: Chain Removal
BREVA V1100 - ABS Engine Chain removal • Remove the engine assembly. • Remove the alternator. • Clearly indicate the distribution timing marks that should be restored at the next refitting (left cylinder TDC). • Using the adequate tool, lock the igni- tion crown.
Page 121 BREVA V1100 - ABS Engine • Unscrew and remove the central seal- ing nut of the timing system control gear on the crankshaft and collect the washer. • Unscrew and remove the oil pump gear nut and collect the washer. •...
Page 122 BREVA V1100 - ABS Engine • Remove the rocking lever support. • Remove the two rocking lever rods See also 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.
Page 123: Removing The Camshaft
BREVA V1100 - ABS Engine Removing the phonic wheel • Remove the timing chain. • Slide off the tone wheel and collect the plug. See also Chain removal Removing the camshaft • Remove the timing chain. • Remove the tone wheel. •...
Page 124: Installing The Camshaft
BREVA V1100 - ABS Engine • Remove the camshaft. See also Chain removal Removing the phonic wheel Removing the tappets Removing the rods Installing the camshaft NOTE FOR TIMING SYSTEM REFITTING, IT IS NECESSARY TO HEAT THE ENGINE WITH A SUITABLE HEATER IN ORDER TO INSERT THE CAMSHAFT CORRECTLY AND WITHOUT DAMAGING IT.
Page 125: Installing The Chain
BREVA V1100 - ABS Engine Installing the chain For the installation of the three gears and of the timing chain carry out the operations indicated in section "Timing". Cam timing • On the crankcase, fit the crankshaft and the camshaft. •...
Page 126 BREVA V1100 - ABS Engine • Place the shim washer adequately so that the timing chain do not wear out the crankcase. • Fit the three timing system gears and the chain aligning the references on the camshaft and crankshaft gears. •...
Page 127 BREVA V1100 - ABS Engine • Turn the oil pump shaft and introduce the gear pulling woodruff key. • Introduce the chain tensioner. • Remove the flywheel locking tool. • Check the crankshaft rotation. • Fit the rocking levers. Specific tooling 12.91.18.01 Tool to lock the flywheel and the starting ring gear Timing To check distribution timing, follow these instruc-...
Page 128 BREVA V1100 - ABS Engine • With a screw, fasten the specific arrow to the threaded hole to the left of the crankcase. Specific tooling 17.94.75.60 Arrow to control ignition timing • Fit the dial gauge support and then the gauge itself on the left outer spark plug hole.
Page 129 BREVA V1100 - ABS Engine • Observing the timing system diagram, check timing considering that: A - intake start opens 22° before TDC B - exhaust end closes 24° after TDC C - exhaust start opens 52° before BDC D - intake end closes 54° after BDC •...
Page 130 BREVA V1100 - ABS Engine • Refit the spark plugs and finish the refit. Specific tooling 981006 Graduated dial hub 19.92.96.00 Graduated dial to control ignition timing 17.94.75.60 Arrow to control ignition timing Measuring air gap • Undo and remove the two screws and remove the sensor.
Page 131: Removing The Cylinder
BREVA V1100 - ABS Engine • 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. Subtract the plain washer value from this measurement to obtain the clearance between the sensor and the tone wheel.
Page 132: Disassembling The Piston
BREVA V1100 - ABS Engine • Slide off the cylinder from the stud bolts, paying attention not to damage the piston. See also Removing the cylinder head Disassembling the piston NOTE THE OPERATIONS DESCRIBED BELOW REFER TO ONE HEAD REMOVING ONLY BUT APPLY TO BOTH HEADS.
Page 133: Fitting The Piston
BREVA V1100 - ABS Engine • 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 134: Installing The Cylinder
BREVA V1100 - ABS Engine • 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 135: Installing The Cylinder Head
BREVA V1100 - ABS Engine • Place the gasket on the cylinder base. • Fit the head. See also Fitting the piston Installing the cylinder head Installing the cylinder head • Fit the valves if they have been previ- ously removed. •...
Page 136 BREVA V1100 - ABS Engine • Using the suitable special tool, screw the inner spark plug. Specific tooling 05.90.19.30 Inner spark plug removal • Insert the washer and screw the joint of the pipe that delivers oil to the head . •...
Page 137 BREVA V1100 - ABS 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 head cover ENG - 137...
Page 138 BREVA V1100 - ABS 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 139 BREVA V1100 - ABS 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 140: Connecting Rods
BREVA V1100 - ABS 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 141 BREVA V1100 - ABS 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. Checking shaft parallelism Check shafts for squaring before fitting them.
Page 142: Installing The Crankshaft
BREVA V1100 - ABS 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 143 BREVA V1100 - ABS 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 144 BREVA V1100 - ABS 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 145 BREVA V1100 - ABS 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 146 BREVA V1100 - ABS 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. • Remove the thermostatic valve. ENG - 146...
Page 147 BREVA V1100 - ABS Engine • Unscrew and remove the pressure re- lief valve plug. • Remove the pressure relief valve com- ponents Refitting the oil sump • Place the pressure relief valve compo- nents correctly. • Screw the pressure relief valve plug. ENG - 147...
Page 148 BREVA V1100 - ABS Engine • In case of overpressure, the engine oil goes back into the oil sump through the hole indicated in the picture. • Place the thermostatic valve. CHECK THAT THE ENGINE OIL PASSAGE HOLE IS NOT CLOGGED.
Page 149 BREVA V1100 - ABS Engine • Place a new gasket and refit the mesh filter tightening the two screws. • Tighten the two screws. • Place the oil sump cover. • Tighten the four screws. • Refit the oil sump on the base. •...
Page 150 BREVA V1100 - ABS Engine • Remove the clamp. • Release the two straps retaining the oil breather pipe. • Remove the two oil breather pipes. • Unscrew and remove the oil return pipe positioning screw. • Release the oil return pipe ENG - 150...
Page 151 BREVA V1100 - ABS Engine • Remove the complete blow-by system. ENG - 151...
Page 152: Index Of Topics
INDEX OF TOPICS P SUPP OWER SUPPLY...
Page 153: Circuit Diagram
BREVA V1100 - ABS 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 - 153...
Page 154 BREVA V1100 - ABS 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 155 BREVA V1100 - ABS 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 156 BREVA V1100 - ABS 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 157 BREVA V1100 - ABS 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 158 BREVA V1100 - ABS 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.) NGINE PARAMETER READING SCREEN PAGE Specification Desc./Quantity...
Page 159: Device Status
BREVA V1100 - ABS 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). EVICE STATUS Specification Desc./Quantity...
Page 160: Errors Display
BREVA V1100 - ABS 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 161: Adjustable Parameters
BREVA V1100 - ABS 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. RAM memory Possible internal control unit error.
Page 162 INDEX OF TOPICS SUSP USPENSIONS...
Page 163: Front Fork
BREVA V1100 - ABS 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.
Page 164: Removing The Fork Legs
BREVA V1100 - ABS 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 165 BREVA V1100 - ABS 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 166 BREVA V1100 - ABS 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 167: Draining Oil
BREVA V1100 - ABS 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 168: Disassembling The Fork
BREVA V1100 - ABS 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 169 BREVA V1100 - ABS 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. CAUTION BE CAREFUL NOT TO DAMAGE THE SLEEVE RIM.
Page 170: Checking The Components
BREVA V1100 - ABS 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. If over the value, replace the stem.
Page 171 BREVA V1100 - ABS 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 172 BREVA V1100 - ABS 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 173 BREVA V1100 - ABS 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 174: Filling Oil
BREVA V1100 - ABS 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 175: Installing The Fork Legs
BREVA V1100 - ABS 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. SUSP - 175...
Page 176 BREVA V1100 - ABS 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 177 BREVA V1100 - ABS 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 178: Steering Bearing
BREVA V1100 - ABS 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 179 BREVA V1100 - ABS 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 180 BREVA V1100 - ABS 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 181 BREVA V1100 - ABS 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 182: Index Of Topics
INDEX OF TOPICS CHAS HASSIS...
Page 183: Swinging Arm
BREVA V1100 - ABS Chassis Swinging arm Removing • To remove the fork, first remove both footrest supporting plates and the ex- haust silencer. • Slide off the rear brake calliper from the disc and release the brake pipe. • Release the cable harness from the clamps and remove the speed sensor.
Page 184 BREVA V1100 - ABS 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 185 BREVA V1100 - ABS 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 186 BREVA V1100 - ABS 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 187 BREVA V1100 - ABS 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 188 BREVA V1100 - ABS 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 189 BREVA V1100 - ABS 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 190 BREVA V1100 - ABS 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 191 BREVA V1100 - ABS 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 192 BREVA V1100 - ABS 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 193 BREVA V1100 - ABS 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). CAUTION MAKE SURE THE STOP RING IS IN ITS SEAT.
Page 194 BREVA V1100 - ABS 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). Assemble the bearings to the wheel axle.
Page 195 BREVA V1100 - ABS 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. Clean the casing faying surfaces carefully.
Page 196 BREVA V1100 - ABS 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 - 196...
Page 197 BREVA V1100 - ABS 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 198 BREVA V1100 - ABS 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. Screw the cap to the prescribed torque.
Page 199 BREVA V1100 - ABS 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. Fit the cap in its seat.
Page 200 BREVA V1100 - ABS Chassis Casing unit removal Remove the cover (20). Remove the plug (3) to drain out the oil. Lift the cap (10). CHAS - 200...
Page 201 BREVA V1100 - ABS 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 - 201...
Page 202: Troubleshooting
BREVA V1100 - ABS 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 surface of the wheel axle seal spoiled or damaged tool 2.
Page 203 BREVA V1100 - ABS 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.
Page 204 BREVA V1100 - ABS 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 fork. • Tighten the four screws with their spacers and the dust-protection ring.
Page 205: Index Of Topics
INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 206 BREVA V1100 - ABS Braking system Foreword key: 1. Front brake pipe 2. Oil pipe screw 3. Aluminium gasket 4. Front brake pipe 5. Control unit/pump 6. Brake pipe 7. Rear brake pipe 8. Screw 9. Bleed valve and cover 10.
Page 207: Operating Diagram
BREVA V1100 - ABS Braking system Operating diagram ABS SYSTEM DESCRIPTION The ABS system is a device to avoid wheels lock- ing in case of emergency braking, increasing ve- hicle braking stability when compared to a tradi- tional braking system. Sometimes when the brake is operated, the tyre locks with a consequent loss of grip, which makes it difficult to control the vehicle.
Page 208 BREVA V1100 - ABS Braking system At engine start-up, the ABS warning light (7) comes on and remains on provided that the vehicle does not exceed 5 km/h (3.1 mph). If the warning light remains on permanently, it means that a mal- function has been detected and the ABS has been deactivated.
Page 209 BREVA V1100 - ABS Braking system key: The black arrow indicates brake fluid path when the ABS system is not working. The white arrow indicates the brake fluid path when the ABS system is working. 2) ABS Control unit 4) Front brake calliper 5) Front brake pump 6) Rear brake pump 10) Rear brake calliper...
Page 210: Abs Operation
BREVA V1100 - ABS Braking system 17) Rear inlet valve ABS OPERATION General specifications: • The front circuit is similar to the rear circuit. • The ABS inlet valve (16 - 17) is normally open and it is closed only when the system inter- venes to avoid wheel locking.
Page 211 BREVA V1100 - ABS Braking system ISO screen page This screen page shows general data regarding the control unit, for example software type, map- ping, control unit programming date ISO SCREEN PAGE Specification Desc./Quantity ISO Code C1EF Manufacturer serial number 540ABS01 Server algorithm SW codes 39607...
Page 212: Errors Display
BREVA V1100 - ABS Braking system 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). EVICE STATUS Specification Desc./Quantity...
Page 213 BREVA V1100 - ABS Braking system ERRORS DISPLAY Specification Desc./Quantity Front speed sensor open circuit or short circuit - see (DIAGNOSIS) Rear speed sensor open circuit or short circuit - see (DIAGNOSIS) Front speed sensor coherence - see (DIAGNOSIS) Rear speed sensor coherence - see (DIAGNOSIS) ABS motor pump - see (DIAGNOSIS)
Page 214 BREVA V1100 - ABS Braking system If functioning is correct, proceed to the next check Checks: check the 10A fuse and wiring coming from the key panel (disconnect the ABS module con- nector and with the key set to ON, check if there is battery voltage in pin 18). Solution: restore the fuse or the wiring FRONT SPEED SENSOR OPEN CIRCUIT OR SHORT CIRCUIT AXONE ERROR Description of the defect: the control unit detects an abnormal voltage in the front speed sensor signal.
Page 215 BREVA V1100 - ABS Braking system Checks: check the tone wheel is not distorted (it should not be deformed or damaged). Solution: replace tone wheel If functioning is correct, proceed to the next check Checks: check the speed sensor position and integrity. Solution: position the speed sensor correctly or replace it.
Page 216 BREVA V1100 - ABS Braking system Description of the defect: the control unit detects a failure in the electric supply voltage. Checks: check if the voltage is too low (below 9.4V. Solution: charge or replace the battery. If functioning is correct, proceed to the next check Checks: check if the voltage is too high (over 16.8V) Solution: replace the voltage regulator Modulator •...
Page 217 BREVA V1100 - ABS Braking system plungers. The four nipples (1 - 2) in the ABS control unit should be unscrewed only when the unit is replaced. CAUTION WHEN THE ABS CONTROL UNIT IS REPLACED, IT IS SUPPLIED ALREADY FILLED WITH BRAKE FLUID;...
Page 218: Rear Brake Pads
BREVA V1100 - ABS Braking system 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 BRAKE LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS.
Page 219 BREVA V1100 - ABS Braking system 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. • Remove the pin. •...
Page 220 BREVA V1100 - ABS 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 221 BREVA V1100 - ABS 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 222 BREVA V1100 - ABS 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 223: Index Of Topics
INDEX OF TOPICS BODYW ODYWORK...
Page 224 BREVA V1100 - ABS 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 225 BREVA V1100 - ABS 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 226 BREVA V1100 - ABS 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 227 BREVA V1100 - ABS Bodywork • Disconnect the connector. • Disconnect the fuel pipe. • Remove the fuel tank by sliding it off and back. BODYW - 227...
Page 228 INDEX OF TOPICS PRE DE DELIVERY...
Page 229 BREVA V1100 - ABS 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 front and rear brake calliper retainer unit front and rear wheel unit engine - chassis retainers...
Page 230 BREVA V1100 - ABS 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. CAUTION TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.
Page 231: Static Test
BREVA V1100 - ABS 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 - Starter operation (if present) - Minimum holding (turning the handlebar) - Uniform turning of the steering...
Page 232 ABS: 206, 210 Air filter: 33 Air temperature sensor: 54, 56 Battery: 47, 52 Brake: 217, 218 Brake pads: 217, 218 Centre stand: Chain: 120, 123–125 Clutch: 92, 95–97, 105, 107, 108 Coil: 55 Crankcase: 19, 138 Crankshaft: 19, 138, 140, 142 Cylinder: 18, 111, 113, 116, 131–135, 139 Desmodromic drum: 94 Display: 160, 212...
Page 233 Maintenance: 8, 28, 217 Oil filter: 32 Oil pressure sensor: 56 Oil sump: 144, 147 Primary shaft: 87, 93, 95 Rear wheel: Recommended products: 20 Secondary shaft: 89, 94, 95 Side stand: Speed sensor: 52 Stand: Start-up: 47 Starter motor: 82, 104 Tank: 225 Transmission: 12, 29 Tyres: 14...

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