MOTO GUZZI Breva V1100 Workshop Manual
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MOTO GUZZI Breva V1100 Workshop Manual

MOTO GUZZI Breva V1100 Workshop Manual

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Summary of Contents for MOTO GUZZI Breva V1100

  • Page 1 workshopmanual...
  • Page 2 INTRODUCTION Breva V1100 INTRODUCTION 0 - 1...
  • Page 3 INTRODUCTION Breva V1100 TABLE OF CONTENTS 0.1. INTRODUCTION .............................. 3 0.1.1. FOREWORD ............................. 3 0.1.2. REFERENCE MANUALS .......................... 4 0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS ..................5 0 - 2...

  • Page 4: Introduction

    DEPT., which will be pleased to help, as well as providing you with updates and technical modifications regarding the vehicle. Moto Guzzi s.p.a. reserves the right to make changes to its products at any time, barring any such changes as may alter the essential features of a product as specified in the relevant manual.

  • Page 5: Reference Manuals

    INTRODUCTION Breva V1100 0.1.2. REFERENCE MANUALS PARTS CATALOGUES guzzi part# (description) GU077_00 OWNER'S MANUALS guzzi part# (description) 05.90.00.30 05.90.00.31 CHASSIS WORKSHOP MANUAL aprilia part# (description) 8140856 8140857 8140858 8140859 8140860 8140861 8CM0077 8CM0078 0 - 4...

  • Page 6: Abbreviations/Symbols/Conventions

    INTRODUCTION Breva V1100 0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS = number < = less than > = greater than ≤ = less than or equal to ≥ = greater than or equal to = approximately ∞ = infinity °C = degrees Celsius (centigrade) °F = degrees Fahrenheit ±...
  • Page 7 INTRODUCTION Breva V1100 T.C.E.I. = cheese-head Allen screw T.E. = hexagonal head T.P. = flat head screw = Twin Spark Ignition UPSIDE- DOWN = inverted fork = Volt = Watt Ø = diameter 0 - 6...
  • Page 8 GENERAL INFORMATION Breva V1100 GENERAL INFORMATION 1 - 1...

  • Page 9: Table Of Contents

    GENERAL INFORMATION Breva V1100 TABLE OF CONTENTS 1.1. STRUCTURE OF THE MANUAL........................3 1.1.1. CONVENTIONS USED IN THE MANUAL ....................3 1.1.2. SAFETY WARNINGS ..........................4 1.2. GENERAL RULES............................5 1.2.1. BASIC SAFETY RULES ..........................5 1.3. DANGEROUS ELEMENTS..........................8 1.3.1.

  • Page 10: Structure Of The Manual

    GENERAL INFORMATION Breva V1100 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. For quick reference, see the summary of sections.

  • Page 11: Safety Warnings

    GENERAL INFORMATION Breva V1100 1.1.2. SAFETY WARNINGS The symbols and warnings used throughout this manual have the following meanings: Safety warning. When you find this symbol on the vehicle or in the manual, be careful of the potential risk of personal injury. Disregarding the instructions identified by this symbol may compromise the safety of the user, the motorcycle and third parties.

  • Page 12: General Rules

    GENERAL INFORMATION Breva V1100 1.2. GENERAL RULES 1.2.1. BASIC SAFETY RULES CARBON MONOXIDE When an operation must be performed with the engine running, position the motorcycle outdoors in a well-ventilated area. Never run the engine in an enclosed place. Use an exhaust emission extraction system when working indoors.
  • Page 13 GENERAL INFORMATION Breva V1100 HYDROGEN GAS AND BATTERY ELECTROLYTE DANGER The battery electrolyte is a toxic, caustic substance containing sulfuric acid and thus able to cause severe burns in case of contact. Wear close-fitting gloves and protective clothing when handling this fluid.
  • Page 14 NOTE All bearings must run 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 Breva V1100 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. Refueling and maintenance operations should be carried out in a well-ventilated area, with the engine off.
  • Page 16 GENERAL INFORMATION Breva V1100 BRAKE FLUID NOTE This vehicle is fitted with front and rear disc brakes. Each brake system is operated by an independent hydraulic circuit. The information provided below applies to both brake systems. DANGER Do not drive the vehicle if the brakes are worn or not operating correctly. The brakes are the vehicle’s most important safety component and using the vehicle with the brakes in less than perfect operating condition comprises a high probability of traffic accident, which can result in serious injury or death.
  • Page 17 GENERAL INFORMATION Breva V1100 TIRES WARNING An over inflated tire results in a hard, uncomfortable and less secure ride. Over inflation also affects grip, especially on curves and wet surfaces. An under inflated tire (insufficient pressure) can slip on the wheel rim, resulting in loss of control.

  • Page 18: Running-In

    GENERAL INFORMATION Breva V1100 1.4. RUNNING-IN 1.4.1. RUNNING-IN Proper engine running in is essential to preserving engine life and performance over time. Twisty roads and gradients are ideal to break in engine, suspension and brakes effectively. Varying speed frequently is also recommended.

  • Page 19: Position Of The Serial Numbers

    GENERAL INFORMATION Breva V1100 1.5. POSITION OF THE SERIAL NUMBERS 1.5.1. POSITION OF THE SERIAL NUMBERS These numbers are necessary for vehicle registration. IMPORTANT: Altering the vehicle's identification numbers is punishable by law with heavy fines and penalties. Altering the frame number voids the warranty.

  • Page 20: Usa Version

    GENERAL INFORMATION Breva V1100 1.6. USA VERSION 1.6.1. POSITION OF THE ADHESIVE WARNING LABELS 1 - 13...
  • Page 21 GENERAL INFORMATION Breva V1100 1 - 14...
  • Page 22 GENERAL INFORMATION Breva V1100 1 - 15...
  • Page 23 GENERAL INFORMATION Breva V1100 Muffler stamping. 1 - 16...

  • Page 24: California Evaporative Emission System

    GENERAL INFORMATION Breva V1100 1.6.2. CALIFORNIA EVAPORATIVE EMISSION SYSTEM The system consists of: Fuel tank Fuel tank breather line Breather line 1-way ventilation valve Breather line (to carbon canister) Carbon canister Drain line Fitting Breather line 10. Tee 11. Drain line 12.
  • Page 25 PERIODIC MAINTENANCE Breva V1100 PERIODIC MAINTENANCE 2 - 1...
  • Page 26 PERIODIC MAINTENANCE Breva V1100 TABLE OF CONTENTS 2.1. TECHNICAL INFORMATION..........................3 2.1.1. TECHNICAL DATA............................ 3 2.1.2. SCHEDULED MAINTENANCE CHART ....................5 2.1.3. LUBRICANT TABLE ..........................7 2.1.4. TIGHTENING TORQUE SETTINGS ......................8 2.1.5. SPECIAL TOOLS ............................ 12 2.1.6. ARRANGEMENT OF THE MAIN ELEMENTS..................13 2.1.7.

  • Page 27: Technical Information

    PERIODIC MAINTENANCE Breva V1100 2.1. TECHNICAL INFORMATION 2.1.1. TECHNICAL DATA DIMENSIONS Length 2195 mm (86.4 in.) Width 870 mm (34.2 in.) Maximum height 1125 mm (44.3 in.) Seat height 800 mm (31.5 in.) Minimum ground clearance 185 mm (7.3 in.) Wheelbase 1495 mm (58.8 in.)
  • Page 28 PERIODIC MAINTENANCE Breva V1100 SUSPENSIONS Front hydraulic telescopic fork Ø 45 mm (1.77 in). Front travel 120 mm (4.72 in.) Rear single-sided with progressive leverage, monoshock adjustable in rebound and with ergonomic knob for spring preload adjustment. Wheel travel 110 mm (4.33 in.)

  • Page 29: Scheduled Maintenance Chart

    Breva V1100 2.1.2. SCHEDULED MAINTENANCE CHART OPERATIONS TO BE CARRIED OUT BY THE Moto Guzzi Authorized dealer (CAN BE CARRIED OUT BY THE USER AS WELL). 1 = check and clean, adjust, lubricate or change, if necessary; 2 = clean;...
  • Page 30 PERIODIC MAINTENANCE Breva V1100 OPERATIONS TO BE CARRIED OUT BY THE Moto Guzzi Authorized dealer. 1 = check and clean, adjust, lubricate or change, if necessary; 2 = clean; 3 = replace; 4 = adjust. NOTE Carry out the maintenance operations more frequently if you use the vehicle in rainy and dusty areas, on uneven ground, or for racing.

  • Page 31: Lubricant Table

    PERIODIC MAINTENANCE Breva V1100 2.1.3. LUBRICANT TABLE LUBRICANT PRODUCT Engine oil RECOMMENDED: RACING 4T 5 W 40 As an alternative to recommended oils, top brand oils meeting or exceeding CCMC G-4 A.P.I. SG specifications can be used. Transmission fluid RECOMMENDED:...

  • Page 32: Tightening Torque Settings

    PERIODIC MAINTENANCE Breva V1100 2.1.4. TIGHTENING TORQUE SETTINGS DESCRIPTION FRAME ECU + coil plate fasteners M6x20 ECU fasteners M6x35 Fasteners for tank rubber blocks to frame M8x12 Gearbox-to-frame fastening Coil fastener M4x25 Engine fastener M12x50 Left and right footrest plate upper fastener to frame...
  • Page 33 PERIODIC MAINTENANCE Breva V1100 DESCRIPTION FRONT SUSPENSION Speed sensor fastener M6x16 Hose plate to bottom yoke fastener M5x16 Fork leg to bottom/top yoke screw M8x25 Steering tube ring nut M35x1 manual + Steering stem locking ring nut M35x1 90 degrees...
  • Page 34 PERIODIC MAINTENANCE Breva V1100 DESCRIPTION BRAKE SYSTEMS Front system Right and left front brake caliper fastener M10x28 Rear system Rear brake caliper fastener M10x30 Rear brake lever pivot Loctite 243 Rear brake fluid reservoir fastener SWP5x20 Rear brake fluid tank support-to-plate fastener...
  • Page 35 PERIODIC MAINTENANCE Breva V1100 DESCRIPTION FRAME / FAIRINGS Front Air scoop to tank fastener M5x9 Lug-to-engine fastening M8x25 Right to left lug fastener M5x9 Front mudguard fastener M5x12 Rear Tail guard + side body panels fastener M5x9 Tail guard-to-grab handle fastening...

  • Page 36: Special Tools

    PERIODIC MAINTENANCE Breva V1100 2.1.5. SPECIAL TOOLS Pos. Guzzi part# (tool description and function) 05.91.26.30 (tool for tightening ring nut on swingarm shaft) AP8140190 (tool for steering tightening) 2 - 12...

  • Page 37: Arrangement Of The Main Elements

    PERIODIC MAINTENANCE Breva V1100 2.1.6. ARRANGEMENT OF THE MAIN ELEMENTS LEFT SIDE Key: Headlight Instrument panel Left rear-view mirror Fuel tank filler plug Fuel tank Left side body panel Main fuse carrier (30A) Battery Rider/Passenger seat Passenger grab handle Tool kit compartment...
  • Page 38 PERIODIC MAINTENANCE Breva V1100 RIGHT SIDE Key: Rear stop switch Glove compartment Compartment Auxiliary fuse carrier Right side body panel Rear brake fluid reservoir Air filter Right rear-view mirror Front brake fluid reservoir Engine oil filter Rear brake lever Rider right footrest...

  • Page 39: Location Of Instruments/Controls

    PERIODIC MAINTENANCE Breva V1100 2.1.7. LOCATION OF INSTRUMENTS/CONTROLS Key: Clutch control lever Ignition switch/steering lock ( Instruments and indicators Front brake lever Throttle grip ABS enabling/disabling push-button (only for vehicles fitted with ABS) Hazard emergency indicator push-button Handgrip heating enabling/disabling push-button (OPT)
  • Page 40 PERIODIC MAINTENANCE Breva V1100 INSTRUMENTS AND INDICATORS Key: Green direction indicator warning light ( Amber ABS warning light ( ) (Anti-lock Braking System) Red alarm warning light Green neutral warning light (N) Amber side stand down warning light ( )

  • Page 41: Maintenance Operations

    PERIODIC MAINTENANCE Breva V1100 2.2. MAINTENANCE OPERATIONS 2.2.1. CHANGING ENGINE OIL AND OIL FILTER CHECKING AND TOPPING UP WARNING Check the engine oil level when the engine is hot. NOTE Letting the engine idle with the vehicle at standstill is not the correct procedure to warm the engine and engine oil up to operating temperature for an oil check.
  • Page 42 PERIODIC MAINTENANCE Breva V1100 • Unscrew and remove the filler plug (3). • Drain the oil into the container and let all the oil drip out for several minutes. • Check the sealing washers of the drain plug (2) and replace if worn.

  • Page 43: Gearbox Oil

    PERIODIC MAINTENANCE Breva V1100 2.2.2. GEARBOX OIL CHECKING AND TOPPING UP • Keep the vehicle upright with both wheels on the ground. • Unscrew and remove the level plug (1). • The correct level is just below the hole of the level plug (1).

  • Page 44: Gearbox Fluid

    PERIODIC MAINTENANCE Breva V1100 2.2.3. GEARBOX FLUID CHECKING AND TOPPING UP WARNING Check the gearbox oil level when the engine is hot. NOTE Letting the engine idle with the vehicle at standstill is not the correct procedure to warm engine and engine oil up to operating temperature for an oil check.

  • Page 45: Cleaning The Air Filter

    PERIODIC MAINTENANCE Breva V1100 2.2.4. CLEANING THE AIR FILTER • Remove the fuel tank (see REMOVING THE FUEL TANK). • Disconnect the connector on the end of the air temperature sensor. • Slide out the oil breather hose. • Loosen and remove the five screws.

  • Page 46: Adjusting The Valve Clearance

    PERIODIC MAINTENANCE Breva V1100 2.2.5. ADJUSTING THE VALVE CLEARANCE When the timing system is noisy, check clearance between valves and rocker arms. NOTE Adjust clearance when the engine is cold, with the piston at top dead centre (TDC) during the compression stroke (valves closed).

  • Page 47: Front Brake

    PERIODIC MAINTENANCE Breva V1100 2.2.6. FRONT BRAKE BLEEDING Any air trapped in the hydraulic circuit will act as a cushion and take up most of the pressure applied by the master cylinder; this will impair the operation of the brake calipers and reduce braking efficiency.
  • Page 48 PERIODIC MAINTENANCE Breva V1100 • Remove both pins. • Remove the vibration damper. • Remove one pad at a time. WARNING Do not operate the brake lever when the pads are not in place or the caliper pistons might come off their housing, thus causing brake fluid leakage.

  • Page 49: Rear Brake

    PERIODIC MAINTENANCE Breva V1100 2.2.7. REAR BRAKE BLEEDING Any air trapped in the hydraulic circuit will act as a cushion and take up most of the pressure applied by the master cylinder; this will impair the operation of the brake calipers and reduce braking efficiency.
  • Page 50 PERIODIC MAINTENANCE Breva V1100 • Turn the pin and slide out the split pin. • Remove the split pin. • Remove the pin. • Remove one pad at a time. WARNING Do not operate the brake lever when the pads...
  • Page 51 FUEL SYSTEM Breva V1100 FUEL SYSTEM 3 - 1...
  • Page 52 FUEL SYSTEM Breva V1100 TABLE OF CONTENTS 3.1. FUEL SYSTEM ..............................3 3.1.1. FUEL SUPPLY SYSTEM DIAGRAM ......................3 3.1.2. REMOVING THE FUEL TANK ........................4 3.1.3. REMOVING THE AIR BOX........................6 3.2. INJECTION ............................... 8 3.2.1. INJECTION SYSTEM DIAGRAM ......................8...

  • Page 53: Fuel System

    FUEL SYSTEM Breva V1100 3.1. FUEL SYSTEM 3.1.1. FUEL SUPPLY SYSTEM DIAGRAM Key: Complete fuel tank Fuel hose Throttle body Fitting Three-way union Hose 3 - 3...

  • Page 54: Removing The Fuel Tank

    FUEL SYSTEM Breva V1100 3.1.2. REMOVING THE FUEL TANK • Remove the seat. • Working on either side, loosen and remove the screw. • Working on either side, raise and slide out the side panel from the pin to remove it.
  • Page 55 FUEL SYSTEM Breva V1100 • Raise the fuel tank and slide the hoses out of "T" fitting. • Disconnect the connector. • Disconnect the fuel hose. • Slide out the fuel tank from behind to remove it. 3 - 5...

  • Page 56: Removing The Air Box

    FUEL SYSTEM Breva V1100 3.1.3. REMOVING THE AIR BOX • Remove the fuel tank, see (REMOVING THE FUEL TANK). • Disconnect the connector on the end of the air temperature sensor. • Slide out the oil breather hose. • Loosen and remove the two oil recovery tank screws.
  • Page 57 FUEL SYSTEM Breva V1100 • Move the oil recovery tank to one side. • Loosen and remove the two air box front screws. • Working on either side, loosen the clamp and remove the coupling from the throttle body. •...

  • Page 58: Injection

    FUEL SYSTEM Breva V1100 3.2. INJECTION 3.2.1. INJECTION SYSTEM DIAGRAM 3 - 8...
  • Page 59 FUEL SYSTEM Breva V1100 Key: Electronic control unit Ignition switch Battery Fuel pump Coils Instrument panel Air temperature sensor Throttle position sensor Injectors Engine temperature sensor Crankshaft position sensor Oxygen sensor Side stand Bank angle sensor 3 - 9...
  • Page 60 ENGINE Breva V1100 ENGINE 4 - 1...
  • Page 61 ENGINE Breva V1100 TABLE OF CONTENTS 4.1. REMOVING AND REFITTING THE ENGINE ....................3 4.1.1. REMOVING THE ENGINE ........................3 4.1.2. REFITTING THE ENGINE ........................12 4.1.3. TIGHTENING TORQUE SETTINGS ....................... 21 4 - 2...

  • Page 62: Removing And Refitting The Engine

    ENGINE Breva V1100 4.1. REMOVING AND REFITTING THE ENGINE 4.1.1. REMOVING THE ENGINE • Before removing the engine, first remove the air box, the sump guard and disconnect the battery. • Remove the swingarm together with the bevel gears. •...
  • Page 63 ENGINE Breva V1100 • Disconnect the throttle cables. • Disconnect the stepper motor connector. • Disconnect the connector on the end of the engine temperature sensor. 4 - 4...
  • Page 64 ENGINE Breva V1100 • Disconnect the connector on the end of the throttle position sensor. • Disconnect the connector on the end of the rpm sensor. • Disconnect the generator connector. 4 - 5...
  • Page 65 ENGINE Breva V1100 • Disconnect the connector on the end of the neutral sensor. • Release and remove the two screws. • Remove the starter motor protection. • Loosen and remove the screw. • Disconnect the ground cables. 4 - 6...
  • Page 66 ENGINE Breva V1100 • Disconnect the starter motor connectors. • Disconnect the oxygen sensor connector. • Prepare a container. • Release the clutch bleed hose. • Drain all clutch fluid. • Loosen and remove the clutch fluid hose screw, set aside the washer.
  • Page 67 ENGINE Breva V1100 • Disconnect the horn connectors. • Loosen and remove the radiator top stud bolt. • Loosen and remove the lower pin nut, set aside the washer. • Remove the lower pin, set aside the washer. 4 - 8...
  • Page 68 ENGINE Breva V1100 • Remove the center stand. • Loosen the clamp. • Loosen and remove the screws and set aside the washers. • Remove the exhaust manifolds. 4 - 9...
  • Page 69 ENGINE Breva V1100 • Remove the catalytic converter. • Fit the engine support stand. • Working on either side, loosen and remove the front screw. • Remove wiring ties. • Loosen and remove the two oil vapor hose screws. •...
  • Page 70 ENGINE Breva V1100 • Remove the upper pin, set aside the washer. • Partially lower the engine. • Disconnect the connector on the end of the oil pressure sensor. • Completely lower the engine. 4 - 11...

  • Page 71: Refitting The Engine

    ENGINE Breva V1100 4.1.2. REFITTING THE ENGINE • Secure the vehicle frame to a lift, lift the engine and set in position. • During this operation, restore the oil pressure transmitter connection. • Install the upper pin with washer. •...
  • Page 72 ENGINE Breva V1100 • Working on either side, tighten the front screw. • Refit the catalytic converter. • Fit the exhaust manifolds. • Fit the washers and tighten the nuts 4 - 13...
  • Page 73 ENGINE Breva V1100 • Tighten the clamp. • Position the center stand. • Fit the lower pin with washer. • Fit the washer and tighten the engine bottom nut to the specified torque. 4 - 14...
  • Page 74 ENGINE Breva V1100 • Position the oil cooler. • Tighten the top stud bolt • Connect the horn connectors. • Secure the clutch fluid hose using the screw and washers. • Fit the clutch bleed hose. • Fill the clutch system with fluid.
  • Page 75 ENGINE Breva V1100 • Connect the oxygen sensor connector. • Fit the starter motor connector. • Tighten the nut and fit the rubber cap. • Fit the ground cables. • Tighten the screw. 4 - 16...
  • Page 76 ENGINE Breva V1100 • Fit the starter motor protection. • Tighten the two screws. • Connect the connector on the end of the neutral sensor. • Connect the generator connectors. 4 - 17...
  • Page 77 ENGINE Breva V1100 • Connect the connector on the end of the rpm sensor. • Connect the connector on the end of the throttle position sensor. • Connect the connector on the end of the engine temperature sensor. • Connect the stepper motor connector.
  • Page 78 ENGINE Breva V1100 • Correctly route the throttle cables and adjust play. • Connect the injector connectors. • Connect the four spark plug caps. 4 - 19...
  • Page 79 ENGINE Breva V1100 • Refit the complete swingarm, the reinforcement bar, the connecting rods, the brake caliper and the rear wheel. 4 - 20...

  • Page 80: Tightening Torque Settings

    ENGINE Breva V1100 4.1.3. TIGHTENING TORQUE SETTINGS DESCRIPTION FRAME ECU + coil plate fasteners M6x20 ECU fasteners M6x35 Fasteners for tank rubber blocks to frame M8x12 Gearbox-to-frame fastening Coil fastener M4x25 Engine fastener M12x50 Left and right footrest plate upper fastener to frame...
  • Page 81 CYCLE PARTS Breva V1100 CYCLE PARTS 5 - 1...
  • Page 82 CYCLE PARTS Breva V1100 TABLE OF CONTENTS 5.1. FRONT FORK..............................3 5.1.1. DIAGRAM ..............................3 5.1.2. REMOVING THE FORK LEGS........................4 5.1.3. CHANGING THE FRONT FORK FLUID....................7 5.1.4. DISASSEMBLING THE FORK LEG ......................10 5.1.5. CHECKING THE COMPONENTS ......................12 5.1.6.

  • Page 83: Front Fork

    CYCLE PARTS Breva V1100 5.1. FRONT FORK 5.1.1. DIAGRAM Key: Screw Right sleeve Left sleeve Upper bushing Retainer Seal Snap ring Dust seal Buffer 10. Washer 11. Screw 12. Dowel 13. Complete plug 14. Counter spring 15. Complete damper rod 16.

  • Page 84: Removing The Fork Legs

    CYCLE PARTS Breva V1100 5.1.2. REMOVING THE FORK LEGS • Loosen the front mudguard screws and remove it. • Loosen the speed sensor screw, remove the wiring ties. • Remove the speed sensor. • Loosen the front caliper screws and remove the calipers.
  • Page 85 CYCLE PARTS Breva V1100 • Loosen the wheel shaft pinch bolts. • Lightly tap with a mallet on the wheel shaft so as to let the holes come out on the opposite side. • Remove the wheel shaft with a screwdriver inside the shaft holes.
  • Page 86 CYCLE PARTS Breva V1100 • Set aside the front wheel spacer on the right side. • Support the fork and loosen the top and bottom yoke screws. • Slide out the fork leg. 5 - 6...

  • Page 87: Changing The Front Fork Fluid

    CYCLE PARTS Breva V1100 5.1.3. CHANGING THE FRONT FORK FLUID NOTE The operations below apply to both fork legs. Periodically change the fork fluid, see (REGULAR SERVICE INTERVALS CHART). NOTE During oil drainage and filling operations, the fork leg and its inner parts should be clamped in a vice; be careful not to tighten excessively or damage them;...
  • Page 88 CYCLE PARTS Breva V1100 • Let oil drain off completely. • Set aside the preload tube. NOTE Push the rod inside the sleeve so that oil will flow out more easily. • Carefully check every part of the leg and make sure nothing is damaged.
  • Page 89 CYCLE PARTS Breva V1100 • Install the preload tube and the spring. • Start the plug onto stanchion tube, pay attention not to damage O-ring. • Tighten cap to the specified torque. 5 - 9...

  • Page 90: Disassembling The Fork Leg

    CYCLE PARTS Breva V1100 5.1.4. DISASSEMBLING THE FORK LEG • Drain all oil from the stanchion, see (CHANGING THE FRONT FORK FLUID). • Tighten the sleeve in a vice. • Loosen the bottom screw and remove it with its gasket.
  • Page 91 CYCLE PARTS Breva V1100 • Slide out the stanchion from the sleeve together with the lower bushing, the seal, the retainer, the top bushing and the complete damper. NOTE It is possible that some parts stay inside the sleeve while sliding the rod out of the sleeve; in this case it will be necessary to remove them.

  • Page 92: Checking The Components

    CYCLE PARTS Breva V1100 5.1.5. CHECKING THE COMPONENTS STANCHION Inspect the sliding surface for scoring and/or scratching. Eliminate minor scoring with wet sand paper (grain size 1). Replace the stanchion if badly scored. Check for stanchion buckling using a dial gauge.
  • Page 93 CYCLE PARTS Breva V1100 lower bushing; damper rod. Change any component which is badly worn or damaged. WARNING Remove from bushing possible impurities, pay attention not to damage the surface. When reassembling, replace the following components with new ones: seal;...
  • Page 94 CYCLE PARTS Breva V1100 O-ring in the cap. 5 - 14...

  • Page 95: Reassembling The Front Fork

    CYCLE PARTS Breva V1100 5.1.6. REASSEMBLING THE FRONT FORK WARNING All components should be carefully washed and blown dry with compressed air before refitting. • Overhaul, where necessary. • Install the damper unit with counter spring and ring in the sleeve.
  • Page 96 CYCLE PARTS Breva V1100 • Fit the retainer and the lubricated seal. • Using a suitable drift, push the seal fully home in the sleeve. • Insert the snap ring. • Fit the dust seal. • Pour some oil inside the leg and make sure it fills up all inner channels of the damper rod.

  • Page 97: Installing The Fork Legs

    CYCLE PARTS Breva V1100 5.1.7. INSTALLING THE FORK LEGS • Install the fork leg. • Install the wheel shaft so that fork legs are aligned. • Tighten the screws onto the fork plates to the specified torque. 5 - 17...
  • Page 98 CYCLE PARTS Breva V1100 • Slide out the wheel shaft. • Position the wheel together with spacer on the right side. • Install the pin. • Tighten the clamp screws (nut side) to lock the wheel shaft. • Fit the washer on the wheel shaft.
  • Page 99 CYCLE PARTS Breva V1100 • Fit the brake calipers and tighten the screws to the specified torque. WARNING After installing the brake calipers, pull the front brake lever a few times • Fit the speed sensor. • Tighten the speed sensor screw.

  • Page 100: Tightening Torque Settings

    CYCLE PARTS Breva V1100 5.1.8. TIGHTENING TORQUE SETTINGS DESCRIPTION FRONT SUSPENSION Speed sensor fastener M6x16 Hose plate to bottom yoke fastener M5x16 Fork leg to bottom/top yoke screw M8x25 Steering tube ring nut M35x1 manual + Steering stem locking ring nut...

  • Page 101: Adjusting Bearing Play

    CYCLE PARTS Breva V1100 5.2. ADJUSTING BEARING PLAY 5.2.1. ADJUSTING BEARING PLAY • Loosen the top bolt on the steering tube. • Working on both handlebars, remove the bottom screw fastening fork plate. • Working on both handlebars, remove the two top screws fastening the fork plate.
  • Page 102 CYCLE PARTS Breva V1100 • Working on either side, remove the screw securing the cover below the instrument panel. • Raise the instrument panel cover. Pay attention not to force hazard button cables and temperature sensor cables. • Remove the top screw securing the headlight subframe.
  • Page 103 CYCLE PARTS Breva V1100 • Move headlight subframe forward centimeters, together with the headlight and instrument panel. • Working on either side, remove the screw securing the fork legs to the steering head. • Slide out the steering head, moving it toward the instrument panel.
  • Page 104 CYCLE PARTS Breva V1100 • Loosen the top ring nut. WARNING When refitting, tighten the top ring nut finger- tight and then slightly force until the ring nut grooves are aligned. • Remove the safety washer. NOTE Prepare the suitable special tool (OPT): AP8140190 (tool for steering tightening) •...

  • Page 105: Tightening Torque Settings

    CYCLE PARTS Breva V1100 5.2.2. TIGHTENING TORQUE SETTINGS DESCRIPTION FRONT SUSPENSION Speed sensor fastener M6x16 Hose plate to bottom yoke fastener M5x16 Fork leg to bottom/top yoke screw M8x25 Steering tube ring nut M35x1 manual + Steering stem locking ring nut...

  • Page 106: Frame

    CYCLE PARTS Breva V1100 5.3. FRAME 5.3.1. LEFT FOOTREST PLATE • To remove the left footrest plate first secure the vehicle front end using the low front stand (OPT) and the vehicle rear end using slings and a hoist. •...
  • Page 107 CYCLE PARTS Breva V1100 • Slide out the gear shift lever, set aside the shim and O- ring. • Loosen and remove the two upper screws. WARNING Make sure you place the screws in the correct position: the shortest one is at the rear.

  • Page 108: Right Footrest Plate

    CYCLE PARTS Breva V1100 5.3.2. RIGHT FOOTREST PLATE • To remove the right footrest plate, first secure the vehicle front end using the low front stand (OPT) and the vehicle rear end using slings and a hoist. • Remove the right side body panel, see (REMOVING THE FUEL TANK).
  • Page 109 CYCLE PARTS Breva V1100 • Loosen and remove the two upper screws. WARNING Make sure you place the screws in the correct position: the shortest one is at the rear. • Disconnect rear brake lever switch connector. • Remove the right footrest plate.

  • Page 110: Tightening Torque Settings

    CYCLE PARTS Breva V1100 5.3.3. TIGHTENING TORQUE SETTINGS DESCRIPTION FRAME ECU + coil plate fasteners M6x20 ECU fasteners M6x35 Fasteners for tank rubber blocks to frame M8x12 Gearbox-to-frame fastening Coil fastener M4x25 Engine fastener M12x50 Left and right footrest plate upper fastener to frame...
  • Page 111 ELECTRICAL SYSTEM Breva V1100 ELECTRICAL SYSTEM 6 - 1...
  • Page 112 ELECTRICAL SYSTEM Breva V1100 TABLE OF CONTENTS 6.1. ELECTRIC SYSTEM ............................3 6.1.1. ELECTRIC COMPONENTS ........................3 6.1.2. WIRING DIAGRAM..........................12 6 - 2...
  • Page 113 ELECTRICAL SYSTEM Breva V1100 6.1. ELECTRIC SYSTEM 6.1.1. ELECTRIC COMPONENTS 6 - 3...
  • Page 114 ELECTRICAL SYSTEM Breva V1100 1 Coil primary resistance: 0.9 – 1.1 Ω (measured across pins 1 and secondary resistance: 6.5 – 7.2 KΩ. 2 Instrument panel Service + Key Right turn indicator control Oil sensor High beam input Select 1...
  • Page 115 ELECTRICAL SYSTEM Breva V1100 3 FUEL PUMP Fuel pump: Power input: 3.5 A (to be measured across pins 1 and 2 with 12V) Fuel sensor Resistance: 250-300 Ω (to be measured across pins 3 and 4 with fuel level equal to 0 liters) 4 INJECTOR Resistance: 14Ω...
  • Page 116 ELECTRICAL SYSTEM Breva V1100 7 TAIL LIGHT 8 Battery 12 V – 18 Ampere/hour 9 MAIN FUSES f - From battery to voltage regulator (30 A). g - From battery to key and auxiliary fuses c - d (30 A).
  • Page 117 ELECTRICAL SYSTEM Breva V1100 11 INTAKE AIR TEMPERATURE SENSOR NTC-type sensor resistance: 3.7 KΩ (at 20°C – 68°F) 12 ENGINE SPEED SENSOR inductive-type sensor, with shielding cable. Winding resistance: 650 Ω (to be measured across pins 1 and 2). Output voltage: 0-5 V (to be measured when cranking).
  • Page 118 ELECTRICAL SYSTEM Breva V1100 15 ECU Model: Magneti Marelli IAW 5 AM2 Black connector pinout (engine) Service Not used Not used TPS signal Not used Engine temperature signal Not used Not used Not used Stepper motor (+) Right cylinder coil control...
  • Page 119 ELECTRICAL SYSTEM Breva V1100 Service Not used Not used CAN – H line (ECU/instrument panel) Not used Oxygen sensor signal Not used Vehicle speed signal input Not used Not used "Engine stop" signal input Starting signal input CAN – L line (ECU/instrument panel)
  • Page 120 ELECTRICAL SYSTEM Breva V1100 18 IMMOBILIZER ANTENNA 19 SPEED SENSOR Active inductive sensor 3-pin connector (Power supply – Signal - Ground) 20 GENERATOR Single-phase generator with regulated voltage Maximum charge 40A (550W) Charge voltage 14.2 - 14.8 V (5000 rpm)
  • Page 121 ELECTRICAL SYSTEM Breva V1100 22 STARTER MOTOR starting input: about 100 A 6 - 11...
  • Page 122 ELECTRICAL SYSTEM Breva V1100 6.1.2. WIRING DIAGRAM 6 - 12...
  • Page 123 ELECTRICAL SYSTEM Breva V1100 Key: Wire color coding: Multiple connectors Orange Clutch switch Light blue Starter relay Blue Light relay White Right dimmer switch Yellow HAZARD button LED Gray HAZARD button Brown Warning horn Black Left dimmer switch 10. Instrument panel air temperature thermistor Pink 11.
  • Page 124 TRANSMISSION Breva V1100 TRANSMISSION 7 - 1...
  • Page 125 TRANSMISSION Breva V1100 TABLE OF CONTENTS 7.1. SWINGARM..............................3 7.1.1. REMOVING THE SWINGARM ........................3 7.1.2. CHECK ..............................6 7.1.3. REFITTING THE SWINGARM........................7 7.1.4. TIGHTENING TORQUE SETTINGS ......................9 7.2. TRANSMISSION BOX ............................ 10 7.2.1. REMOVAL ............................... 10 7.2.2.

  • Page 126: Swingarm

    TRANSMISSION Breva V1100 7.1. SWINGARM 7.1.1. REMOVING THE SWINGARM • Before removing the swingarm, first remove both footpeg plates and the exhaust silencer. • Remove the cover. • Engage the first gear. • Loosen and remove the four screws, set aside the spacers.
  • Page 127 TRANSMISSION Breva V1100 • Loosen and remove the reinforcement bar nut. • Remove the screw. • Secure the reinforcement bar to the frame using a clamp. • Remove the dust cover clip. • Loosen the two screws on the swingarm clamp.
  • Page 128 TRANSMISSION Breva V1100 • Request the assistance of a second person, slide out the shaft and remove the swingarm together with the cardan joint. 7 - 5...

  • Page 129: Check

    TRANSMISSION Breva V1100 7.1.2. CHECK • Check that the cardan joint is in good condition, that the gear teeth engaging in the union grooves and the joint grooves are not damaged or worn. Replace the joint if necessary. • Check that the rubber bellow is not cut or pierced.

  • Page 130: Refitting The Swingarm

    TRANSMISSION Breva V1100 7.1.3. REFITTING THE SWINGARM • Smear some grease all along the swingarm shaft. • Fit the ring nut to the swingarm shaft and tighten snugly. • Support the swingarm, fit the cardan joint, match the holes and simultaneously fit the shaft completely with the assistance of a second person.
  • Page 131 TRANSMISSION Breva V1100 • Fit the dust cover on gearbox. • Secure the dust cover using a new clamp. • Fit the reinforcement bar in its seat. • Fit the screw. • Tighten the reinforcement bar nut. • Fit the connecting rod to the swingarm.

  • Page 132: Tightening Torque Settings

    TRANSMISSION Breva V1100 7.1.4. TIGHTENING TORQUE SETTINGS DESCRIPTION SWINGARM Swingarm clamp-to-bushing fastening 6x25 Swingarm-to-bevel gear fastening M10x35 Linkage-to-bevel gear fastening M10x50 Linkage to frame fastener M10x50 Swingarm shaft-to-swingarm fastener M12x1.25 Preload bushing to swingarm shaft fastener M25x1.5 7 - 9...

  • Page 133: Transmission Box

    TRANSMISSION Breva V1100 7.2. TRANSMISSION BOX 7.2.1. REMOVAL • Before removing the transmission box, first remove the exhaust silencer and the rear wheel. • Loosen and remove the reinforcement bar nut. • Remove the screw. • Secure the reinforcement bar to the frame using a clamp.
  • Page 134 TRANSMISSION Breva V1100 • Remove the cardan joint and the transmission box. 7 - 11...

  • Page 135: Reassembly

    TRANSMISSION Breva V1100 7.2.2. REASSEMBLY • Fit the transmission box on the swingarm. Make sure that the cardan joint fits correctly. • Tighten the four screws to the specified torque, following a cross pattern. • Fit the reinforcement bar in its seat.
  • Page 136 TRANSMISSION BREVA V1100 7.2.3 Disassembly SYMBOLOGY DESCRIPTION SYMBOLS WARNING/DANGER REMOVE/INSTALL seals-gaskets-filters OIL FILLING OR OIL LEVEL/OIL DRAIN LUBRICATION/GREASING ADJUSTMENTS/MEASUREMENTS tightening torques-preloads-backlash SPECIAL TOOLS SEALING/LOCKING FLUIDS APPLICATION MARKING DISASSEMBLY/ASSEMBLY OF BULKY PARTS OR SUBASSEMBLIES WARNING: respect assembly orientation CLEANING CAREFULLY APPLY PRESSURIZED FLUID...
  • Page 137 TRASMISSIONE BREVA V1100 TIGHTENING TORQUES 30 Nm - B 30 Nm - B 20 Nm - B Sez. A-A 170 Nm - B 2 Nm - C 35 Nm - B 0.6 Nm - A 7 - 14...
  • Page 138 TRANSMISSION BREVA V1100 HOUSING GROUP DISASSEMBLY Remove the plug (20). Remove the plug (3) to drain the oil. 7 - 15...
  • Page 139 TRANSMISSION BREVA V1100 Lift the boot (10). Remove the clamps (9) and (11). Remove the boot (14). Remove the screws (16). Set aside the ring (15). 7 - 16...
  • Page 140 TRANSMISSION BREVA V1100 Remove the bolts (7). Remove the housing (4). Remove the clamp (12). Remove the boot (14). Set aside the ring (13). 7 - 17...
  • Page 141 TRANSMISSION BREVA V1100 Remove the support group (8). ASSEMBLY Assemble the dowel pin (21) to the housing (18) with the special tool and a hammer. Assemble the housing (18) on the special fastening tool. Clean with care the housings contact surfaces.
  • Page 142 TRANSMISSION BREVA V1100 Insert the support group (8) into the housing (18). Assemble the ring (13) with the boot (14). Assemble the boot (14) to the support (8). Assemble the clamp (12). Lock the clamp (12) with suitable pliers. 7 - 19...
  • Page 143 TRANSMISSION BREVA V1100 Apply the prescribed sealant to the housing (18). Assemble a new seal ring (1) using the special tool. Lubricate the seal ring (1). Assemble two stud bolts with thread in the threaded holes on the housing (18), as shown in figure.
  • Page 144 TRANSMISSION BREVA V1100 Assemble the fastening screws (7). Tighten the screws (7) to the prescribed torque. Remove excess sealant. Assemble the ring (15) to the housing. Assemble the fastening screws (16) to the prescribed torque. Assemble the plug (3) and the washer (2).
  • Page 145 TRANSMISSION BREVA V1100 Assemble the breather (6) and the washer (5). Tighten the breather (6) to the prescribed torque. Fill the transmission with the prescribed oil. Assemble the plug (3) and the washer (2). Tighten the plug to the prescribed torque.
  • Page 146 TRANSMISSION BREVA V1100 WHEEL SHAFT GROUP DISASSEMBLY Remove the bearing (1) from the wheel shaft (3) with suitable extractor. Turn the group over. Remove the bearing (10) from the wheel shaft (3) with suitable extractor. ASSEMBLY Heat the bearings (1) and (10) at 100°C.
  • Page 147 TRANSMISSION BREVA V1100 Turn the group over. Assemble the bearing (10) to the wheel shaft (3). 7 - 24...
  • Page 148 TRANSMISSION BREVA V1100 PINION GROUP DISASSEMBLY Remove the lock ring (1) from the ring nut (2). Unscrew the ring nut (2) with the special wrench (s4). Remove the ring nut (2), then remove the seal ring from the ring nut.
  • Page 149 TRANSMISSION BREVA V1100 Grease the seal ring (3). Assemble the ring nut (2). Tighten the ring nut (2) with the special wrench (s4) to the prescribed torque. Insert the locking ring (1) into the ring nut (2) in the shown position.
  • Page 150 TRANSMISSION BREVA V1100 Assembly position of the locking ring (1). Warning: the locking ring (1) must be pushed in its seat. 7 - 27...
  • Page 151 TRANSMISSION BREVA V1100 SUPPORT GROUP DISASSEMBLY Remove the bushing (1) with a punch. Overturn the support (5) and remove the other bush (8). 7 - 28...
  • Page 152 TRANSMISSION BREVA V1100 Remove the seal ring (2) and (7) with a screwdriver. Note: destructive operation for the seal ring. Remove from the support (5) the lock rings (3) and (6) with suitable pliers. Remove the spherical joint (4) with a suitable pad and a hammer.
  • Page 153 TRANSMISSION BREVA V1100 Insert into the support (5) the lock ring (3) with suitable pliers. Assemble the new seal rings (2) and (7) by hand. Assemble the bushing (1). Drive in the bushing (1) with a plastic hammer. Turn over the support (5) and assemble the other bush (8)

  • Page 154: Troubleshooting

    TRANSMISSION BREVA V1100 TROUBLESHOOTING This chapter is a descriptive and explanatory guide to common transmission problems. This guide suggests the correct repair procedures to be followed. Problem Cause Action Oil leakage from the wheel shaft 1. Radial shaft seal incorrectly mounted 1.
  • Page 155 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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