MOTO GUZZI BREVA V850 Guide

SERVICE STATION MANUAL
854316
BREVA - V850

SERVICE STATION
MANUAL
BREVA - V850
While the basic features as described and illustrated in this manual remain unchanged, Moto Guzzi
s.p.a. reserves the right to introduce changes to their own models at any time. All rights regarding
electronic data storage, total or partial reproduction or adaptation of this manual by any means are
reservedforallCountries.Thirdpartyproductsorservicesreferredtointhismanualshouldbeconsidered
onlyinformative andare notbinding. MotoGuzzi s.p.a.shall notbe liablefor anyfunctions oruse ofthese
products.

SERVICE STATION MANUAL
BREVA - V850
This manual provides the main information to carry out regular maintenance operations on your scooter.
This manual is intended to Moto Guzzi Dealers and their qualified mechanics; several concepts have
been deliberately omitted as they are considered unnecessary. As it is not possible to include complete
mechanical notions in this manual, users should have basic mechanical knowledge or minimum
knowledge about the procedures involved when repairing scooters. Without this knowledge, repairing or
checking the vehicle may be inefficient or even dangerous. As the vehicle repair and check procedures
are not described in detail, be extremely cautious so as not to damage components or injure individuals.
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. These changes will be introduced in the subsequent editions of the manual. In case of
need or further queries on repair and check procedures, consult Moto Guzzi CUSTOMER
DEPARTMENT, which will be prepared to provide any information on the subject and any further
communications on updates and technical changes related to the vehicle.
NOTE Provides key information to make the procedure easier to understand and carry out.
CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.
Personal safety Failure to completely observe these instructions will result in serious risk of personal
injury.
Safeguarding the environment Sectionsmarked with thissymbol indicatethe correctuse of thevehicle
to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious
damage to the vehicle and sometimes even the invalidity of the guarantee

INDEX OF TOPICS
CHARACTERISTICS CHAR
SPECIAL TOOLS S-TOOLS
MAINTENANCE MAIN
ELECTRICAL SYSTEM ELE SYS
ENGINE FROM VEHICLE ENG VE
ENGINE ENG
POWER SUPPLY P SUPP
SUSPENSIONS SUSP
CHASSIS CHAS
BRAKING SYSTEM BRAK SYS
BODYWORK BODYW
PRE-DELIVERY PRE DE

INDEX OF TOPICS
CHARACTERISTICS CHAR

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.
CAUTION
EXHAUSTEMISSIONSCONTAINCARBONMONOXIDE,APOISONOUS GASWHICHCANCAUSE
LOSS OF CONSCIOUSNESS AND EVEN DEATH.
Fuel
CAUTION
THE FUEL USED TO POWER INTERNAL COMBUSTION ENGINES IS HIGHLY FLAMMABLE AND
MAY BE EXPLOSIVE UNDER CERTAIN CONDITIONS. IT IS THEREFORE RECOMMENDED TO
CARRY OUT REFUELLING AND MAINTENANCE PROCEDURES IN A VENTILATED AREA WITH
THE ENGINE SWITCHED OFF. DO NOT SMOKE DURING REFUELLING AND NEAR FUEL VA-
POURS, AVOIDING ANY CONTACT WITH NAKED FLAMES, SPARKS OR OTHER SOURCES
WHICH MAY CAUSE THEM TO IGNITE OR EXPLODE.
DO NOT DISPERSE FUEL IN THE ENVIRONMENT.
KEEP OUT OF THE REACH OF CHILDREN
Hot components
The engine and the exhaust system components become very hot and remain hot for some time after
the engine has been switched off. When handling these components, wear insulating gloves or wait
until the engine and the exhaust system have cooled down.
Used engine oil and transmission oil
CAUTION
IT IS ADVISABLE TO WEAR PROTECTIVE IMPERMEABLE GLOVES WHEN SERVICING THE VE-
HICLE.
THE ENGINE OR GEARBOX OIL MAY CAUSE SERIOUS INJURIES TO THE SKIN IF HANDLED
FOR PROLONGED PERIODS OF TIME AND ON A REGULAR BASIS.
WASH YOUR HANDS CAREFULLY AFTER HANDLING OIL.
HAND THE OIL OVER TO OR HAVE IT COLLECTED BY THE NEAREST USED OIL RECYCLING
COMPANY OR THE SUPPLIER.
DO NOT DISPOSE OF OIL IN THE ENVIRONMENT
KEEP OUT OF THE REACH OF CHILDREN
BREVA - V850 Characteristics
CHAR - 7

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. BRAKE AND CLUTCH FLUIDS ARE EXTREMELY HARMFUL FOR YOUR
EYES. IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THEM IMMEDIATELY
WITH ABUNDANT COLD, CLEAN WATER AND SEEK MEDICAL ADVICE.
KEEP OUT OF THE REACH OF CHILDREN
Battery electrolyte and hydrogen gas
CAUTION
THE BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND AS IT CONTAINS SULPHURIC ACID,
IT CAN CAUSE BURNS WHEN IN CONTACT WITH THE SKIN. WHEN HANDLING BATTERY
ELECTROLYTE, WEAR TIGHT-FITTING GLOVES AND PROTECTIVE APPAREL. IN THE EVENT
OF SKIN CONTACT WITH THE ELECTROLYTIC FLUID, RINSE WELL WITH PLENTY OF CLEAN
WATER. IT IS PARTICULARLY IMPORTANT TO PROTECT YOUR EYES BECAUSE EVEN TINY
AMOUNTSOFBATTERYACIDMAYCAUSEBLINDNESS.IFTHEFLUIDGETSINCONTACTWITH
YOUR EYES, WASH WITH ABUNDANT WATER FOR FIFTEEN MINUTES AND CONSULT AN EYE
SPECIALIST IMMEDIATELY. THE BATTERY RELEASES EXPLOSIVE GASES; KEEP IT AWAY
FROM FLAMES, SPARKS, CIGARETTES OR ANY OTHER HEAT SOURCES. ENSURE ADE-
QUATE VENTILATION WHEN SERVICING OR RECHARGING THE BATTERY.
KEEP OUT OF THE REACH OF CHILDREN
BATTERY LIQUID IS CORROSIVE. DO NOT POUR IT OR SPILL IT, PARTICULARLY ON PLASTIC
COMPONENTS. ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BAT-
TERY TO BE ACTIVATED.
Maintenance rules
GENERAL PRECAUTIONS AND INFORMATION
When repairing, dismantling and reassembling the vehicle, follow the recommendations given below
carefully.
BEFORE DISASSEMBLING COMPONENTS
•Beforedismantlingcomponents, removedirt, mud,dust and foreignbodies fromthe vehicle.
Use the special tools designed for this bike, as required.
COMPONENTS REMOVAL
•Donot loosen and/ortighten screwsand nutsusing pliers orany othertools thanthe specific
wrench.
•Mark positions on all connection joints (pipes, cables etc.) before separating them, and
identify them with distinctive symbols.
•Each component needs to be clearly marked to enable identification during reassembly.
•Clean and wash the dismantled components carefully using a low-flammability detergent.
•Keep mated parts together since they have "adjusted" to each other due to normal wear.
Characteristics BREVA - V850
CHAR - 8

•Some components must be used together or replaced completely.
•Keep away from heat sources.
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.
•When tightening nuts and screws, start from the ones with the largest section or from the
internal ones, moving diagonally. Tighten nuts and screws in successive steps before ap-
plying the tightening torque.
•Always replace self-locking nuts, washers, sealing rings, circlips, O-rings (OR), split pins
and screws with new ones if their tread is damaged.
•When assembling the bearings, make sure to lubricate them well.
•Check that each component is assembled correctly.
•After a repair or routine maintenance procedure, carry out pre-ride checks and test the ve-
hicle on private grounds or in an area with low traffic density.
•Clean all coupling surfaces, oil guard rims and gaskets before refitting them. Smear a light
layer of lithium-based grease on the oil guard rims. Reassemble oil guards and bearings
with the brand or lot number facing outward (visible side).
ELECTRICAL CONNECTORS
Electric connectors must be disconnected as described below; failure to comply with this procedure
causes irreparable damage to both the connector and the wiring harness:
Press the relative safety clips, if applicable.
•Grip the two connectors and disconnect them by pulling them in opposite directions.
•If any signs of dirt, rust, moisture, etc. are noted, clean the inside of the connector carefully
with a jet of compressed air.
•Ensure that the cables are correctly fastened to the internal connector terminals.
•Then connect the two connectors, ensuring that they couple correctly (if fitted with clips, you
will hear them "click" into place).
CAUTION
DO NOT DISCONNECT CONNECTORS BY PULLING THE CABLES.
NOTE
THE TWO CONNECTORS CAN ONLY BE CONNECTED IN ONE DIRECTION: CONNECT THEM
THE RIGHT WAY ROUND.
TIGHTENING TORQUES
CAUTION
REMEMBERTHATTHETIGHTENINGTORQUESFORALLFASTENINGELEMENTSONWHEELS,
BRAKES, WHEEL AXLES AND ANY OTHER SUSPENSION COMPONENTS PLAY A KEY ROLE
IN ENSURING VEHICLE SAFETY AND MUST COMPLY WITH SPECIFIED VALUES. CHECK THE
BREVA - V850 Characteristics
CHAR - 9

TIGHTENING TORQUES OF FASTENING ELEMENTS ON A REGULAR BASIS AND ALWAYS USE
A TORQUE WRENCH TO REASSEMBLE THESE COMPONENTS. FAILURE TO COMPLY WITH
THESE RECOMMENDATIONS MAY CAUSE ONE OF THESE COMPONENTS TO LOOSEN OR
EVEN DETACH, CAUSING A WHEEL TO LOCK OR COMPROMISING VEHICLE HANDLING. THIS
MAY LEAD TO FALLS, WITH THE RISK OF SERIOUS INJURY OR DEATH.
Running-in
Runningthe engine incorrectly isessential forensuring enginelongevity andfunctionality. Twistyroads
and gradients are ideal for running in the engine, brakes and suspension effectively. Vary your riding
speed during the running in period. This ensures that components operate in "loaded" conditions and
then "unloaded" conditions, allowing the engine components to cool.
CAUTION
THE CLUTCH MAY EMIT A SLIGHT BURNING SMELL WHEN FIRST USED. THIS PHENOMENON
SHOULD BE CONSIDERED NORMAL AND WILL DISAPPEAR AS SOON AS THE CLUTCH
PLATES GET ADAPTED.
ITIS IMPORTANT TO STRAIN ENGINE COMPONENTS DURING RUN-IN, HOWEVER,MAKESURE
NOT TO OVERDO THIS.
CAUTION
THE FULL PERFORMANCE OF THE VEHICLE IS ONLY AVAILABLE AFTER THE SERVICE AT
THE END OF THE RUNNING IN PERIOD.
Follow the guidelines detailed below:
•Do not fully open the throttle grip abruptly at low engine speeds, either during or after the
running in period.
•During the first 100 Km (62 miles) use the brakes gently, avoiding sudden or prolonged
braking. 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.
Vehicle identification
SERIAL NUMBER LOCATION
These numbers are necessary for vehicle registration.
NOTE
ALTERING IDENTIFICATION NUMBERS MAY BE SERIOUSLY PUNISHABLE BY LAW. IN PAR-
TICULAR, MODIFYING THE FRAME NUMBER IMMEDIATELY VOIDS THE WARRANTY.
Characteristics BREVA - V850
CHAR - 10