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

This number is composed by numbers and letters,
as in the example shown below.
ZGULPB000YMXXXXXX
KEY:
ZGU: WMI (World manufacture identifier) code;
LP: model;
B00: version variation;
0: digit free
Yyear of manufacture
M: production plant (M= Mandello del Lario);
XXXXXX: progressive number (6 digits);
CHASSIS NUMBER
The chassis number is stamped on the right side
of the headstock.
ENGINE NUMBER
The engine number is stamped on the left side,
close to the engine oil level check cap.
Dimensions and mass
WEIGHT AND DIMENSIONS
Specification Desc./Quantity
Length 2195 mm (86.4 in)
Width 870 mm (34.2 in)
Maximum height 1125 mm (44.3 in)
Saddle height 800 mm (31.5 in)
Minimum earth clearance 185 mm (7.3 in)
Wheelbase 1495 mm (58.8 in)
Kerb weight 248 kg (547 pounds)
Engine
ENGINE
Specification Desc./Quantity
Type traverse-mounted twin-cylinder four-stroke V 90°
No. of cylinders 2
Cylinder arrangement V 90°
Total engine capacity 877 cm³ (53.5 cu.in)
Bore / stroke 92 x 66 mm (3.6 x 2.6 in)
BREVA - V850 Characteristics
CHAR - 11

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 air
Fuel system Electronic injection (Weber . Marelli) with stepper motor
Diffuser Ø 45 mm (1.77 in)
Fuel Premium unleaded petrol, minimum octane rating 95 (NORM)
and 85 (NOMM)
Timing system diagram: 2 rod valves and rocking levers
Valid values with checking clearance between rocking levers
and valve inlet: 0.10 mm (0.0039 in) outlet: 0.15 mm (0.0059 in)
Transmission
TRANSMISSION
Specification Desc./Quantity
Main transmission with gears, ratio: 23/36 = 1 :0.6389
Gearbox Mechanical, 6 speeds with foot lever on the left hand side of
the engine
Gear ratios: 1st gear : 17/38 = 1 :2.2353
2nd gear : 20/34 = 1:1.7
3rd gear : 23/31 = 1:1.3478
4th gear : 26/29 = 1:1.1154
5th gear : 31/30 = 1:0.9677
6th gear : 29/25 = 1:0.8621
Final drive with U-joint
Ratio 12/44 = 1:3.6667
Capacities
CAPACITY
Specification Desc./Quantity
Engine oil Oil and oil filter change 3600 cm³ (219 cu.in)
Gearbox oil 500 cm³ (30.5 cu.in)
Transmission oil 380 cm³ (23.2 cu.in)
Fuel (reserve included) 23 l (6.1 gal)
Fuel reserve 4 l (1.06 gal)
Fork oil 400 ± 2.5 cm³ (24.4 ± 0.15 in) (for each stem)
Seats 2
Vehicle maximum load 230 Kg (507 pounds) (rider + passenger + luggage)
Electrical system
ELECTRICAL SYSTEM
Specification Desc./Quantity
Outer spark plug NGK BPR6ES
Electrode gap 0.6 - 0.7 mm (0.024 - 0.028 in)
Battery 12 V - 18 Ampere/hour
Alternator (permanent magnet type) 12 V - 550 W
Main fuses 30 A
AUXILIARY FUSES 3A - 15A - 20A
Daylight running light 12V - 5 W
Low-beam light 12 V - 55 W H7
High-beam light 12 V - 65 W H9
Turn indicators 12V - 10 W (orange bulb)
Characteristics BREVA - V850
CHAR - 12

Specification Desc./Quantity
Rear daylight running light/stop light LED
Dashboard lighting LED
License plate light 12V - 5 W
Turn indicator warning light LED
ABS warning light LED
Neutral gear warning light LED
Alarm warning light LED
Side stand down warning light LED
Low fuel warning light LED
High beam warning light LED
Antitheft device warning light LED
Gear shift warning light LED
Frame and suspensions
CHASSIS
Specification Desc./Quantity
Type high strength steel tube chassis
Trail 120 mm (4.72 in)
Headstock angle 25° 30'
Front hydraulic telescopic fork; Ø 45 mm (1.77 in)
Wheel travel 120 mm (4.72 in)
Rear single arm suspension with progressive linkage, single shock
absorber with adjustable rebound and ergonomic knob for
spring preloading adjustment.
Wheel travel 140 mm (5.5 in)
SIZES A AND B
Specification Desc./Quantity
Size A 758.9 +/- 1 mm (29.88 +/- 0.04 in)
Size B 345.5 mm (13.60 in)
Brakes
BRAKES
Specification Desc./Quantity
Front twin Ø 320 mm (12.6 in) stainless steel floating disc, calliper
with 4 different and counteracting plungers
Rear 282 mm (11.1 in) diam. stainless steel disc
BREVA - V850 Characteristics
CHAR - 13

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" 58 W
Inflation pressure (front) 2.5 bar (250 kPa) (36.3 PSI)
Inflation pressure with passenger (front) 2.5 bar (250 kPa) (36.3 PSI)
Rear 180/55 - ZR 17" 73 W
Inflation pressure (rear) 2.8 bar (280 kPa) (40.6 PSI)
Inflation pressure with passenger (rear) 2.8 bar (280 kPa) (40.6 PSI)
Tightening Torques
HEADS
Name Torque in Nm
Oil cap (2) 25 Nm (18.44 lbf ft)
Exhaust system stud bolt (4) 10 Nm (7.38 lbf ft) - Loctite 648
Rocking lever support nut - M10x1.5 (8) 15 Nm (11.06 lbf ft) + 90º + 90º
Rocking lever nut (4) 10 Nm (7.38 lbf ft)
Set screw - TE M6x16 (4) 10 Nm (7.38 lbf ft)
Head cover screw - M6x25 (16) 10 Nm (7.38 lbf ft)
Head fixing screw (4) 15 Nm (11.06 lbf ft) + 90º
Oil temperature sensor 11 Nm (8.11 lbf ft) - Loctite 243
Oil temperature sensor container 11 Nm (8.11 lbf ft) - Loctite 601
Outer Spark plugs 30 Nm (22.13 lbf ft) - Molikote
Spark plug hole cap 11 Nm (8.11 lbf ft)
CRANKCASE
Name Torque in Nm
Crankcase stud bolt - cylinder (8) 25 Nm (18.44 lbf ft)
Transmission side flange stud bolt - M8x66 (3) 35 Nm (25.81 lbf ft)
Transmission side flange stud bolt - M8x75 (2) 35 Nm (25.81 lbf ft)
Crankshaft flange screw - TE M8x25 (14) 25 Nm (18.44 lbf ft)
Timing system cover screw - TCEI M8x55 (4) 25 Nm (18.44 lbf ft)
Timing system cover screw - TCEI M6x30 (10) 10 Nm (7.38 lbf ft)
Oil vapour union screw - TCEI M6x20 (2) 10 Nm (7.38 lbf ft)
Timing system outer cover screw - TCEI M6x16 (4) 10 Nm (7.38 lbf ft)
Screw TSPEI M4x8 (2) 5 Nm (3.69 lbf ft) - Loctite 243
TCEI M6x40 Screw (2) 10 Nm (7.38 lbf ft)
Timing sensor - TCEI M5x12 (2) 6 Nm (4.42 lbf ft)
Crankcase stud bolts - chassis (4) 40 Nm (29.5 lbf ft) - Loctite 601
OIL SUMP
Name Torque in Nm
Cap on oil sump flange (2) 20 Nm (14.75 lbf ft)
Oil pipe on sump 20 Nm (14.75 lbf ft)
Oil sump lower screw - TCEI M6x30 (4) 10 Nm (7.38 lbf ft)
Oil sump screw - TCEI M6x55 (14) 10 Nm (7.38 lbf ft)
Oil sump screw - TCEI M6x60 (2) 10 Nm (7.38 lbf ft)
Oil drainage plug - M10x1 (1) 20 Nm (14.75 lbf ft)
Oil filter (1) 15 Nm (11.06 lbf ft)
Oil filter fitting (1) 40 Nm (29.5 lbf ft) - Loctite 243
Oil pipe in sump 20 Nm (14.75 lbf ft) - Loctite 648
Pressure-relief plug 40 Nm (29.5 lbf ft)
Oil intake filter fixing screw - TCEI M6x16 (1) 10 Nm (7.38 lbf ft) - Loctite 648
Characteristics BREVA - V850
CHAR - 14

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)
Oil delivery pipe screw (1) 17 Nm (12.54 lbf ft)
Oil pressure sensor 45 Nm (33.19 lbf ft)
TIMING SYSTEM
Name Torque in Nm
Camshaft flange screw - TE M6x20 (3) 10 Nm (7.38 lbf ft)
Timing system gear nut on camshaft - M18 (1) 150 Nm (110.63 lbf ft)
Timing system gear nut on crankshaft - M25 (1) 120 Nm (88.51 lbf ft)
Camshaft support screw on timing system cover - TCEI M4x10
(4) 5 Nm (3.69 lbf ft) - Loctite 243
Belt tension 50 Nm (36.88 lb ft)
GENERATOR
Name Torque in Nm
Alternator fixing screw - TCEI M8x45 (1) 22 Nm (16.23 lbf ft)
Alternator fixing nut - M10x1.5 (1) 30 Nm (22.13 lbf ft)
Alternator pulley nut on crankshaft - M16 (1) 80 Nm (59 lbf ft) - Loctite 243
CRANKSHAFT - FLYWHEEL
Name Torque in Nm
Start-up crown fixing screw on flywheel (8) 18 Nm (13.28 lbf ft) - Loctite 243
Connecting rod screw (4) - pre-tightening 40 Nm (29.5 lbf ft)
Connecting rod screw (4) - final tightening 80 Nm (59 lbf ft)
Flywheel fixing screw on crankshaft - M8x25 (6) 42 Nm (30.98 lbf ft) - Loctite 243
GEAR
Name Torque in Nm
Gear shift cable lever nut 10 Nm (7.38 lbf ft)
Gear shift tie rod lever nut on gear pre-selector 10 Nm (7.38 lbf ft)
Gearbox to crankcase fixing nut - M8 (5) 20 Nm (14.75 lbf ft)
TE flanged screw fixing gearbox to crankcase - M8x45 (1) 20 Nm (14.75 lbf ft)
Oil cap M18x1.5 (1) 28 Nm (20.65 lbf ft)
Breather cap (1) 8 Nm (5.9 lbf ft)
Gear in neutral sensor (1) 10 Nm (7.38 lbf ft)
Oil drainage plug - M10x1 (1) 24 Nm (17.7 lbf ft)
Transmission shaft ring nut (1) 100 Nm (73.76 lbf ft)
CHASSIS TO ENGINE UNIT
Name Torque in Nm
M6x40 TCEI DA screw 8 -12 Nm
Reduction 20 Nm
FUEL SUPPLY CONTROL UNIT
Name Torque in Nm
M5x12 TCEI screw 6 -7 Nm
Stainless M5x16 TBEI flanged screw 6 -7 Nm
M6x25 TCEI DA screw 8 -12 Nm
CHASSIS
Name Torque in Nm
Electronic control unit retainer + coil plates 10 Nm
Electronic control unit retainer 10 Nm
Tank support rubber rings to chassis retainer 25 Nm
Gearbox to chassis retainer 80 Nm
Coil retainer 2 Nm
Engine retainer 80 Nm
BREVA - V850 Characteristics
CHAR - 15

Name Torque in 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
Plate ring to plate retainer 6 Nm
Handgrip to chassis fixing screw 25 Nm
Cover to handgrip retainer 25 Nm
FOOTRESTS AND LEVERS
Name Torque in Nm
Footrest rubber retainer 10 Nm
Rod retainer (nut) 10 Nm
Gear shift lever / brake pin retainer 10 Nm
Gear shift lever / pre-selector retainer 10 Nm
Spring hook pin 4 Nm
SIDE STAND
Name Torque in Nm
Stand plate to engine retainer 80 Nm
Side stand retainer pin 10 Nm
Switch fixing screw 10 Nm
Lock nut 30 Nm
CENTRE STAND
Name Torque in Nm
Stand to plates fixing screw 50 Nm
Pipe guide ring to plates fixing screw 10 Nm
FRONT SUSPENSION
Name Torque in Nm
Speed sensor retainer 10 Nm
Tube lock plate to steering base retainer 6 Nm
Fork stem to lower / upper plate retainer 25 Nm
Headstock ring nut 40 Nm
Headstock counter ring nut manual + 90 degrees
Upper yoke fixing cap 100 Nm
Fork hubs closing 10 Nm
REAR SUSPENSION
Name Torque in Nm
Shock absorber to chassis retainer - 8.8 50 Nm
Double connecting rod/shock absorber retainer - 10.9 40 Nm
Single connecting rod/double connecting rod retainer - 10.9 50 Nm
Single connecting rod to chassis retainer - 8.8 50 Nm
Double connecting rod/swingarm retainer - 10.9 50 Nm
AIR FILTER CASING
Name Torque in Nm
Filter casing cover/filter casing bracket 3 Nm
Blow-by tank to filter casing cover retainer 3 Nm
Air temperature sensor retainer 2 Nm
EXHAUST
Name Torque in Nm
Exhaust pipe to engine retainer 25 Nm
Exhaust pipe to compensator retainer (clamp) 10 Nm
Compensator to plate retainer 25 Nm
Compensator to silencer retainer (clamp) 10 Nm
Lambda probe retainer 38 Nm
Silencer to support retainer (screw +nut) 25 Nm
Characteristics BREVA - V850
CHAR - 16

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
FRONT BRAKING SYSTEM
Name Torque in Nm
Front brake right and left calliper retainer 40 Nm
REAR BRAKING SYSTEM
Name Torque in Nm
Rear brake calliper retainer 50 Nm
Rear brake lever pin 15 Nm
Rear brake fluid reservoir retainer 3 Nm
Rear brake fluid reservoir support to plate retainer 10 Nm
Rear brake rod lock nut manual
Brake lever spring to plate retainer 6 Nm
Brake pump retainer 10 Nm
HANDLEBAR AND CONTROLS
Name Torque in Nm
Half-handlebar to steering plate retainer 25 Nm
Handlebar pipes to half-handlebar retainer 25 Nm
Anti-vibration counterweight fastener 10 Nm
ELECTRICAL SYSTEM
Name Torque in Nm
Horn retainer 15 Nm
Speed sensor to front fork retainer 12 Nm
INSTRUMENT PANEL AND LIGHTS
Name Torque in Nm
Instrument panel support to light support retainer 10 Nm
Instrument panel support to fork upper plate retainer 25 Nm
Instrument panel retainer 3 Nm
Light support to fork lower plate retainer 25 Nm
Light + turn indicators retainer 10 Nm
Rear light to handgrip retainer 4 Nm
FUEL PUMP FLANGE
Name Torque in Nm
Tank breather joint 6 Nm
Pump support to tank retainer 4 Nm
FUEL TANK
Name Torque in Nm
Filler to tank retainer 4 Nm
Rear screw fixing the tank to the chassis - M8x45 25 Nm
CHASSIS / FAIRINGS (FRONT)
Name Torque in Nm
Air inlet to tank retainer 4 Nm
Lug to engine retainer 25 Nm
Right to left lug retainer 4 Nm
BREVA - V850 Characteristics
CHAR - 17

Name Torque in 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 25 Nm
Retroreflector to support retainer 4 Nm
Retroreflector support to license plate holder retainer 4 Nm
License plate lamp to license plate holder retainer 4 Nm
FINISHINGS
Name Torque in Nm
Ignition lock retainer - shear head screw - Nm
Ignition lock retainer 25 Nm
SWINGARM
Name Torque in Nm
Swingarm on bushing clamp retainer 10 Nm
Swingarm on bevel gear pair retainer 50 Nm
Reaction rod to bevel gear pair retainer 50 Nm
Reaction rod to chassis retainer 50 Nm
Swingarm bolt to swingarm retainer 60 Nm
Preloading bushing to swingarm bolt retainer 10 Nm
Overhaul data
Assembly clearances
Cylinder - piston assy.
Measurement of the cylinder diameter must be done at three heights, turning the dial gauge 90°.
Check the clearance between the cylinders and pistons; if it exceeds the value specified, it is necessary
to replace cylinders and pistons.
The pistons of an engine must be balanced; a weight difference of up to 1.5 (0.0033 lb) is admitted.
ADMITTED MEASUREMENTS
Specification Desc./Quantity
cylinder diameter 92.000 - 92.020 mm (3.62204 - 3.62282 in)
piston diameter 91.942 - 91.972 mm (3.6197 - 3.6209 in)
fitting clearance 0.048 - 0.068 mm (0.00189 - 0.00268 in)
Characteristics BREVA - V850
CHAR - 18

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:
Upper sealing ring and stepped ring 0.40 - 0.65 mm (0.00158 - 0.00255 in)
Oil scraper ring 0.30 - 0.60 mm (0.00118 - 0.00236 in).
Turn the rings so that the coupling ends are 120 degrees from each other.
Crankcase - crankshaft - connecting rod
CAMSHAFT (CAM) SUPPORT DIAMETER AND THEIR SEATS ON THE CRANKCASE
(TIMING SYSTEM SIDE)
Specification Desc./Quantity
Shaft support diameter 47.000 - 46.984 mm
(1.85039 ÷ 1.84976 inch)
Seat diameter on base 47.025 - 47.050 mm
(1.85137 ÷ 1.85236 inch )
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 ÷ 1.26181 inch)
fitting clearance 0.025 - 0.066 mm
(0.00098 ÷ 0.00260 inch)
BREVA - V850 Characteristics
CHAR - 19

TAPPET-SEAT COUPLING ON CRANKCASE DATA (PRODUCTION)
Specification Desc./Quantity
Seats diameter 22.021 - 22.000 mm
(0.86697 ÷ 0.86614 inch)
Tappet external diameter 21.996 - 21.978 mm
(0.86598 ÷ 0.86527 inch)
Fitting clearances 0.004 - 0.043 mm
(0.00016 ÷ 0.00169 in.)
Recommended products chart
RECOMMENDED PRODUCTS
Product Description Specifications
AGIP RACING 4T 10W-60 Engine oil SAE 10W - 60. As an alternative to rec-
ommended fluids, use top branded oils
with performances that meet or exceed
the requirements of CCMC G-4 API. SG
specifications.
AGIP GEAR SAE 80 W 90 Transmission oil -
AGIP GEAR MG/S SAE 85 W 90 Gearbox oil -
AGIP FORK 7.5W Fork oil SAE 5W / SAE 20W
AGIP GREASE SM2 Lithium grease with molybdenum for
bearings and other points needing lubri-
cation
NLGI 2
Neutral grease or petroleum jelly. Battery poles
AGIP BRAKE 4 / BRAKE 5.1 Brake fluid As an alternative for recommended flu-
ids, use top branded fluids that meet or
exceed the requirements of SAE J1703,
NHTSA 116 DOT 4, ISO 4925 synthetic
fluid specifications.
AGIP BRAKE 4 / BRAKE 5.1 Clutch fluid As an alternative for recommended flu-
ids, use top branded fluids that meet or
exceed the requirements of SAE J1703,
NHTSA 116 DOT 4, ISO 4925 synthetic
fluid specifications.
NOTE
USE ONLY NEW BRAKE FLUID. DO NOT MIX DIFFERENT BRANDS OR TYPES OF OIL WITHOUT
CHECKING THEIR BASE COMPATIBILITY.
Characteristics BREVA - V850
CHAR - 20