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BREVA 750
INTRODUCTION 0
0-1
INTRODUCTION
BREVA 750
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
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INTRODUCTION
BREVA 750
0.1. INTRODUCTION
0.1.1. FOREWORD
This manual provides the information required for normal servicing.
This manual is intended for use by Moto Guzzi Dealers and their qualified mechanics. Certain information has been o-
mitted intentionally, as this manual does not purport to provide a comprehensive treatise on mechanics. The persons
who will use this manual must be fully conversant with the basics of mechanics and with the basic procedures of motor-
cycle repair. Repairing or inspecting a motorcycle when one does not possess such basic knowledge or training could
result in improper servicing and make the motorcycle unsafe to ride. For the same reason, certain basic precautions ha-
ve been omitted in the descriptions of repair and inspection procedures; you are therefore invited to take special care to
avoid damage to motorcycle components or injury to persons. Moto Guzzi s.p.a.'s mission is to enhance the riding plea-
sure of end users through on-going improvement of its products as well as of the relevant technical literature. All Moto
Guzzi s.p.a. Points of Sale and Branches worldwide are kept updated on major engineering changes and modifications
to repair procedures. Such changes and modifications are then reflected in the next release of the relevant manual.
When in doubt about an inspection or repair procedure, please contact the Moto Guzzi SERVICE DEPARTMENT, who
will be glad to provide full information on the procedure in question as well as on any updates or engineering changes
affecting the motorcycle under consideration.
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 this manual.
All rights of storage using electronic means, reproduction and total or partial adaptation, whatever the means adopted,
are reserved in all countries.
The mention of third parties’ products is only made for information purposes, and constitutes no engagement.
Moto Guzzi s.p.a. is not liable in any way for the performance or use of its products.
DECA s.r.l.
via Risorgimento, 23/1 - 48022 Lugo (RA) - Italy
Tel. +39 - 0545 35235
Fax +39 - 0545 32844
E-mail: deca@decaweb.it
www.decaweb.it
On behalf of:
0-3
INTRODUCTION
BREVA 750
PARTS CATALOGUES
part# (description)
GU000 rel.00 BREVA 750 IE (32920010)
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INTRODUCTION
BREVA 750
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INTRODUCTION
BREVA 750
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GENERAL INFORMATION
BREVA 750
GENERAL INFORMATION 1
1-1
GENERAL INFORMATION
BREVA 750
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 WARNINGS...............................................................................................................................5
1.2.1. GENERAL SAFETY RULES.....................................................................................................................5
1.3. HAZARDOUS SUBSTANCES .....................................................................................................................8
1.3.1. WARNINGS.............................................................................................................................................8
1.4. RUNNING-IN ............................................................................................................................................12
1.4.1. RUNNING-IN.........................................................................................................................................12
1.5. LOCATION OF SERIAL NUMBERS...........................................................................................................13
1.5.1. LOCATION OF SERIAL NUMBERS .......................................................................................................13
1-2
GENERAL INFORMATION
BREVA 750
optional
catalytic version
- all versions
MP national certification
SF European certification (EURO 1 limits)
VERSION:
Italy Greece Malaysia
United King- Holland Chile
dom
Austria Switzerland Croatia
Portugal Denmark Australia
Finland Japan United States of America
Belgium Singapore Brazil
Germany Slovenia Republic of South Africa
France Israel New Zealand
Spain South Korea Canada
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GENERAL INFORMATION
BREVA 750
Safety warning. This symbol appears, whether in the manual or on the vehicle itself, to indicate a per-
sonal injury hazard. Non-compliance with the indications given in the messages preceded by this sym-
bol may result in grave risks for your and other people's safety and for the vehicle!
DANGER
Indicates a potential hazard which may result in serious injury or even death.
WARNING
Indicates a potential hazard which may result in minor personal injury or damage to the vehicle.
IMPORTANT: The word "IMPORTANT" in this manual precedes important information or instructions.
1-4
GENERAL INFORMATION
BREVA 750
DANGER
Exhaust emissions contain carbon monoxide, a poisonous gas that may cause loss of consciousness
or even death.
FUEL
DANGER
The fuel used for internal combustion engines is extremely inflammable and in particular conditions it
can become explosive.
It is important to carry out the refueling and the maintenance operations in a well-ventilated area, with
the engine off.
Do not smoke when refueling or in the proximity of sources of fuel vapors. Avoid contact with bare
flames, sources of sparks or any other source which may ignite the fuel or lead to explosion.
DANGER
Wear latex gloves during servicing.
Prolonged or repeated contact with gearbox oil may cause severe skin damage.
Wash your hands thoroughly after handling gearbox oil.
Dispose of gearbox oil through the nearest waste oil reclamation firm or through the supplier.
Wear latex gloves during servicing.
BRAKE FLUID
WARNING
Brake fluid can damage painted, plastic or rubber surfaces. When servicing the brake system, protect
such surfaces with a clean cloth.
Always wear safety glasses when servicing the brake system.
Brake fluid is extremely dangerous in contact with the eyes.
In case of contact with the eyes, rinse abundantly with cool, clean water and immediately seek medi-
cal attention.
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GENERAL INFORMATION
BREVA 750
DANGER
The battery electrolyte is a toxic, caustic substance containing sulphuric acid and thus able to cause
severe burns in case of contact.
Wear close-fitting gloves and protective clothing when handling the battery electrolyte.
If any battery fluid gets on your skin, rinse the affected area with abundant fresh water.
Take special care to protect your eyes - even a small amount of battery fluid can cause blindness. If
battery fluid is spilled into your eyes, flush with abundant water for fifteen minutes and contact an eye
specialist immediately.
If battery fluid is swallowed accidentally, drink abundant water or milk. Immediately seek medical at-
tention and keep drinking milk of magnesia or vegetable oil in the meantime.
The battery gives off explosive gases. Keep the battery well away from any sources of ignition, such
as flames, sparks, or any heat sources.
Make sure the area is well ventilated when servicing or refilling the battery.
DANGER
Do not use open flames when working on the vehicle. Before proceeding to maintain or inspect the
motorcycle, stop the engine and remove the ignition switch key. Ensure that the engine and exhaust
system have cooled down. Wherever possible, place the motorcycle on firm and level ground and lift it
using suitable equipment. Pay special attention to hot engine parts and the exhaust system: burns
hazard.
Do not hold mechanical parts or engine components in the mouth, as some of them are made of toxic
materials.
Unless otherwise specified, re-assembly takes place in the reverse order to disassembly. Where a
procedure is cross-referred to relevant sections in the manual, proceed sensibly to avoid disturbing
any parts unless strictly necessary. Never use abrasive pastes to polish opaque paintwork.
Never use fuel instead of solvent to clean the motorcycle.
Do not use alcohol, petrol or solvents to clean the rubber and plastic parts and the saddle: use only
water and mild soap.
Always disconnect the battery negative (–) lead before soldering any electrical components.
When two or more persons service the same motorcycle together, special care must be taken to avoid
personal injury.
For more details see (HAZARDOUS COMPONENTS)
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GENERAL INFORMATION
BREVA 750
DANGER
Never reuse circlips or snap rings. These parts must always be renewed once they have been disas-
sembled.
When fitting a new circlip or snap ring, open the ends just sufficiently to allow fitment to the shaft.
Make a rule to check that a newly-fitted circlip or snap ring has located fully into its groove.
Never use compressed air to clean bearings.
IMPORTANT: All bearings must run freely with no hardness or noise. Replace any bearings that do not meet these re-
quirements.
- Use ORIGINAL Moto Guzzi SPARE PARTS only.
- Use the specified lubricants and consumables.
- Where possible, lubricate a part before assembly.
- When tightening nuts and bolts, start with the largest or innermost nut/bolt and observe a cross pattern. Tighten
evenly in subsequent steps until achieving the specified torque.
- Replace any self-locking nuts, gaskets, seals, circlips or snap rings, O-rings, split pins, bolts and screws which have
a damaged thread.
- Lubricate bearings abundantly before assembly.
- Make a rule to check that all components you have fitted are correctly in place.
- After repairing the motorcycle and after each service inspection, perform the preliminary checks, and then operate
the motorcycle in a private estate area or in a safe area away from traffic.
- Clean all mating surfaces, oil seal edges and gaskets before assembly. Apply a light coat of lithium grease along the
edges of oil seals. Fit oil seals and bearings with the brand or serial number facing outwards (in view).
ELECTRICAL CONNECTORS
Disconnect electrical connectors as follows: failure to follow the instructions can seriously damage the connectors and
the wiring:
Press down on the locking tab, where fitted.
WARNING
Never separate two connectors by pulling on the wiring.
• Grasp both connectors and pull them in opposite directions until they become separated.
• Remove any dirt, rust, moisture, etc. from inside the connector with compressed air.
• Ensure that the wires are securely crimped to the terminals inside each connector.
IMPORTANT: A connector will only locate properly into the matching connector when it is inserted in the correct mount-
ing position.
• Reconnect the two connectors and ensure that they are fully engaged (if fitted with a locking tab, it should click audi-
bly into place).
TIGHTENING TORQUES
DANGER
Do not forget that the tightening torques of all fastenings on wheels, brakes, wheel spindles and other
suspension components are essential to ensuring safe operation of the motorcycle and must be set to
the indicated values.
Regularly check the tightening torques on all fastenings, and always use a torque wrench when fitting
them.
Failure to observe these instructions can result in parts loosening or coming away, thus jamming a
wheel or creating other problems which could affect the handling of the motorcycle, potentially result-
ing in serious injury or death.
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GENERAL INFORMATION
BREVA 750
FUEL
DANGER
The fuel used for internal combustion engines is extremely inflammable and in particular conditions it
can become explosive.
It is important to carry out the refueling and the maintenance operations in a well-ventilated area, with
the engine off.
Do not smoke when refueling or in the proximity of sources of fuel vapors. Avoid contact with bare
flames, sources of sparks or any other source which may ignite the fuel or lead to explosion.
Take care not to spill fuel out of the filler, or it may ignite when in contact with hot engine parts.
In the event of accidental fuel spillage, make sure the affected area is fully dry before starting the en-
gine. Fuel expands from heat and when left under direct sunlight.
Never fill the tank to the brim. Tighten the filler cap securely after each refueling.
Avoid any contact of the fuel with the skin and the inhalation of vapors; do not swallow fuel or pour it
from a receptacle into another by means of a tube.
DO NOT DISPOSE OF FUEL IN THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
Use only premium-grade unleaded fuel with a minimum octane rating of 95 (N.O.R.M.) and 85 (N.O.M.M.).
LUBRICANTS
DANGER
Correct lubrication is essential to the safety of the motorcycle.
Failure to maintain the lubricant level or the use of incorrect, old or dirty lubricant can cause the en-
gine or transmission to seize, resulting in accidents, serious injury or death.
Prolonged or repeated contact with engine oil may cause severe skin damage.
Wash your hands thoroughly after handling engine oil.
Do not dispose of oil in the environment.
Dispose of engine oil through the nearest waste oil reclamation firm or through the supplier.
WARNING
When filling the vehicle with lubricant, make sure not to spill it. Immediately clean up spilled oil, as it
can damage the motorcycle's paint.
Oil on the tires can make them very slippery and dangerous to use.
In case of oil leaks, do not use the vehicle. Identify the cause of the leak and repair it.
ENGINE OIL
DANGER
Prolonged or repeated contact with engine oil may cause severe skin damage.
Wash your hands thoroughly after handling engine oil.
Do not dispose of oil in the environment.
Dispose of engine oil through the nearest waste oil reclamation firm or through the supplier.
Wear latex gloves during servicing.
DANGER
Modifying the suspension settings or the viscosity of the front fork oil will affect its response. Stan-
dard oil viscosity: SAE 20 W. Choose the oil viscosity to determine the type of response required (SAE
5W for a softer suspension, 20W for a stiffer suspension).
The two grades can also be mixed in varying solutions to obtain the desired response.
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GENERAL INFORMATION
BREVA 750
BRAKE FLUID
IMPORTANT This motorcycle is fitted with two (front and rear) disk brakes with independent hydraulic circuits. The in-
formation provided below applies to both braking systems.
DANGER
Do not use the vehicle if the brakes are worn or malfunctioning! The brakes are the most important
safety component on the vehicle, and using the vehicle with the brakes in less than perfect condition
is very likely to result in an accident, with the risk of serious personal injury or death.
The brakes are significantly less effective on a wet road surface.
DANGER
If the road surface is wet with rain, maintain a double braking distance, inasmuch as both the brakes
themselves and the grip of the tires are significantly less effective in such conditions.
Water on the brakes, whether due to a recent wash or picked up from the wet road surface, puddles or
drains, can result in significantly reduced brake effectiveness.
Failure to observe these instructions can result in serious accidents, with the risk of serious personal
injury or death.
The brakes are essential to your safety. Do not use the vehicle if the brakes are not in perfect working
order.
Always check the brakes before riding the motorcycle.
Brake fluid is an irritant. Avoid contact with eyes or skin.
In the event of accidental contact, wash affected body parts thoroughly. In the event of accidental con-
tact with eyes, contact an eye specialist or seek medical advice.
DO NOT DISPOSE OF THE FLUID IN THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
When handling brake fluid, take care not to spill it onto plastic or paint-finished parts or they will dam-
age.
DANGER
Do not use any brake fluids other than the specified type. Never mix different types of fluids to top up
level, as this will damage the braking system.
Do not use brake fluid from containers which have been kept open or in storage for long periods.
Sudden resistance or clearance problems on the brake levers may be due to troubles in the hydraulic
circuits.
Ensure that the brake discs and friction material have not become contaminated with oil or grease.
This is particularly important after servicing or inspections.
Make sure the brake lines are not twisted or worn.
Avoid accidental ingress of water or dust into the circuit.
Wear latex gloves when servicing the hydraulic circuit.
DISK BRAKES
DANGER
The brakes are the vehicle’s most important safety component.
To ensure your personal safety, they must be in perfect working order and should be checked before
every ride.
Oil or other liquids on the disks will contaminate the brake pads.
Dirty pads must be replaced. A dirty or oily disk should be cleaned with a high quality degreaser.
If the vehicle is often used on wet road surfaces or on dusty or rough tracks, or in case of use in com-
petition, reduce the service intervals by half.
Check the wear of the brake pads.
When the pads are worn, the fluid level in the tank lowers to compensate for the wear.
The front brake fluid reservoir is on the RH side of the handlebar, next to the front brake lever.
The rear brake fluid reservoir is under the RH side fairing.
Do not use the vehicle if the brake system is leaking in any position.
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GENERAL INFORMATION
BREVA 750
COOLANT
DANGER
Coolant is toxic when ingested and is an irritant, contact with eyes or skin may cause irritation.
On the event of contact with the skin or the eyes, rinse repeatedly with abundant water and seek
medical advice. If swallowed, provoke vomiting, rinse the mouth and throat with abundant water and
immediately seek medical attention.
DO NOT DISPOSE OF THE FLUID IN THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
DANGER
Take care not to spill coolant onto hot engine parts. It may ignite and produce invisible flames. Wear
latex gloves when working on the system.
Do not ride when coolant is below the minimum level.
Coolant mixture is a 50% solution of water and anti-freeze. This is the ideal solution for most operating temperatures and
provides good corrosion protection.
This solution is also suited to the warm season, as it is less prone to evaporative loss and will reduce the need for top-
ups.
In addition, less water evaporation means fewer minerals salts depositing in the radiator, which helps preserve the
efficiency of the cooling system.
When the outside temperature drops below freezing, check the coolant circuit frequently and add more anti-freeze (up to
60% maximum) to the solution.
Use distilled water in the coolant mixture. Tap water will damage the engine.
Refer to the chart given below and add water with the quantity of anti-freeze to obtain a solution with the desired freezing
point:
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GENERAL INFORMATION
BREVA 750
TIRES
WARNING
An overinflated tire results in a hard, uncomfortable and less secure ride.
Overinflation also affects grip, especially on curves and in the wet.
An underinflated tire (insufficient pressure) can slip on the wheel rim, resulting in loss of control.
Underinflation also affects grip and handling, as well as braking efficiency.
Tire replacement and repair, and wheel servicing and balancing are delicate operations. They should
be carried out using adequate tools and are best left to experienced mechanics.
New tires may be covered by a thin protective cover which has reduced grip. Ride carefully for the
first few kilometers (miles).
Never use any kind of rubber treatment product on the tires.
In particular, take care not to allow the tire to come into contact with liquid fuel, which rapidly deterio-
rates the tire rubber.
A tire which has come into contact with oil or fuel cannot be cleaned and must be replaced.
DANGER
Certain OEM tires are equipped with wear indicators.
There are various types of wear indicators.
Contact your Dealership for tire checking information.
Check tire wear visually and have the tires replaced when they are worn.
If a tire deflates during a ride, do not attempt to continue the trip.
Avoid sudden braking or steering maneuvers, and do not decelerate rapidly.
Slowly decelerate and move to the edge of the road braking with the engine until you come to a stand-
still.
Failure to observe these instructions can result in serious accidents, with the risk of serious personal
injury or death.
Never use tube tires on tubeless tire rims, or vice versa.
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GENERAL INFORMATION
BREVA 750
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.
This will vary the amount of stress placed on vehicle components continuously, allowing engine parts to cool down when
less stressed.
While it is important to put a certain amount of stress to engine components during the running-in period, it is equally im-
portant to spare the engine at this stage in vehicle's life.
WARNING
Top acceleration performance is only obtained after covering the first 1243 mi (2000 km).
WARNING
After the first 932 mi (1500 km), perform the checks listed in the “post running-in” column of the PE-
RIODIC MAINTENANCE CHART. Failure to perform these checks may lead to personal injury to your-
self or third persons, or vehicle damage.
• Between the first 932 mi (1500 km) and 1243 mi (2000 km), a somewhat brisker riding style is acceptable. Vary
your speed and use peak acceleration for just a few instants, to allow the different components to become properly
seated against one another. However, avoid exceeding 6000 rpm (see chart).
• After 1243 mi (2000 km), the engine will be ready for a more demanding use. However, never exceed the maximum
engine speed allowed (7600 rpm).
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GENERAL INFORMATION
BREVA 750
ENGINE NUMBER
DIGIT MEANING
1. Manufacturer’s identification alphanumeric code
2. Vehicle type
3. Model
4. Country for which the vehicle is intended
5. # = Check digit number
6. Model year
7. Assembling factory designation (M = Mandello)
8. Sequential serial number
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GENERAL TECHNICAL INFORMATION
BREVA 750
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GENERAL TECHNICAL INFORMATION
BREVA 750
TABLE OF CONTENTS
2.1. GENERAL TECHNICAL INFORMATION .....................................................................................................3
2.1.1. TECHNICAL DATA..................................................................................................................................3
2.1.2. SCHEDULED MAINTENANCE CHART....................................................................................................6
2.1.3. LUBRICANT CHART ...............................................................................................................................8
2.1.4. TIGHTENING TORQUES.........................................................................................................................9
2.1.5. SPECIAL TOOLS ..................................................................................................................................11
2.1.6. LOCATION OF MAIN PARTS ................................................................................................................13
2.1.7. LOCATIONS OF CONTROLS / INSTRUMENTS.....................................................................................15
2.1.8. ENGINE OIL AND FILTER CHANGE .....................................................................................................16
2.1.9. SYSTEMS LAYOUT ..............................................................................................................................17
2.1.10. POSITION OF THE WARNING ADHESIVE LABELS...........................................................................22
2.1.11. CALIFORNIA EVAPORATIVE EMISSION SYSTEM............................................................................26
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GENERAL TECHNICAL INFORMATION
BREVA 750
ENGINE
Type Two-cylinder 4-stroke
Number of cylinders Two
Cylinder layout 90° V
Pistons forged, two compression rings, one oil control ring
Bore 3.14 in (80 mm)
Stroke 2.91 in (74 mm)
Total displacement 45.40 cu in (744 cc)
Cooling Air
Air cleaner dry cartridge type
Compression ratio 9.6:1
Maximum horsepower (CE correction) 35.5 kW at 6800 rpm
Maximum torque (CE correction) 40.34 ftlb (54.7 Nm) at 3600 rpm
Engine idle rpm 1100 ± 100 rpm
TIMING
Timing diagram: 2 valves with push-rods and rockers
intake valve opens 18° B.T.D.C.
intake valve closes 50° A.B.D.C.
exhaust valve opens 53° B.B.D.C.
exhaust valve closes 15° A.T.D.C.
Values valid with clearance between rockers 0.006 in (0.15 mm) intake
and valve 0.008 in (0.20 mm) exhaust
FUEL SUPPLY
Type Electronic injection (Weber – Marelli)
Choke Ø 1.42 in (36 mm)
Fuel Premium grade unleaded petrol, minimum octane rating 95 (N.O.R.M.)
and 85 (N.O.M.M.)
STARTING Electric
TRANSMISSION
- clutch dry single disc with cush drive
- primary transmission gear-type, ratio: 16/21 = 1:1.3125
- gearbox 5 gears
- gear ratios:
1st 11/26 = 1:2.3636
2nd 14/23 = 1:1.6429
3rd 18/23 = 1:1.2778
4th 18/19 = 1:1.0556
5th 20/18 = 1:0.9
- final transmission cardan shaft type
- ratio 8/33 = 1:4.825
Lubrication Pressure system, valve adjustment, lobe pump
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GENERAL TECHNICAL INFORMATION
BREVA 750
VEHICLE
FRAME
Type detachable tubular duplex cradle with high yield strength
Trail 4.29 in (109 mm)
Rake 27.5°
SUSPENSION
Front MARZOCCHI hydraulic telescopic fork, Ø 1.57 in (40 mm).
Front wheel travel 130 mm
Rear swing arm in light cast alloy with two dampers, spring adjustable for
pre-load and rebound
Rear wheel travel 4.65 in (118 mm)
BRAKES
Front Stainless steel Ø 12.60 in (320 mm) floating disc, calliper with 4 differ-
entiated and opposing pistons
Rear Stainless steel Ø 10.24 in (260 mm) disc
Brake master cylinder diameter:
- front brake master cylinder Ø 0.51 in (13 mm)
- rear brake master cylinder Ø 0.51 in (13 mm)
Calliper diameters:
- front calliper Ø 1.34 / 1.18 in (34 / 30 mm)
- rear caliper Ø 1.26 in (32 mm)
Total friction surface area:
- front 0.023 ft2 (21.3 cm2)
2 2
- rear 0.017 ft (16.1 cm )
Brake pads compound
- front Frendo 222
- rear Ferodo IP 450
WHEELS
Type 3-spoke diecast in light alloy
Front rim 3” x 17”
Rear rim 3.50” x 17”
TYRES
Type BRIDGESTONE BATLAX or PIRELLI SPORT DAEMON
- front 110/70 ZR 17”
Inflation pressures 32.36 PSI
Inflation pressure with passenger 36.77 PSI
- rear 130/80 ZR 17”
Inflation pressure 35.30 PSI
Inflation pressure with passenger 39.72 PSI
ELECTRICAL SYSTEM
Battery 12 V – 14 Ah
Generator (with permanent magnet) 12 V – 400 W
Main fuses 30 A
Secondary fuses 3 A – 10 A – 15 A
Alternator (permanent magnet) 12 V – 330 W
BULBS
Headlamp low beam / high beam (halogen) 12V – 55/60 W H4
Front parking light 12V – 5 W
Direction indicators 12V – 10 W (RY 10W orange bulb)
Rear parking / brake lights 12V – 5/21 W
Instruments lighting LED
EFI LED
Number plate light 12V – 5 W
2-4
GENERAL TECHNICAL INFORMATION
BREVA 750
WARNING LIGHTS
Neutral LED
Direction indicators LED
Fuel reserve LED
High beam LED
Engine oil pressure LED
SPARK PLUGS
Standard NGK BR8ES
Spark plug gap 0.024 – 0.028 in (0.6 – 0.7 mm)
Resistance 5 KΩ
DIMENSIONS
Length 86.22 in (2190 mm)
Width 28.74 in (730 mm)
Maximum height (at front fairing) 46.26 in (1175 mm)
Seat height 31.10 in (790 mm)
Ground clearance 6.93 in (176 mm)
Wheelbase 57.05 in (1449 mm)
Dry weight 401.24 lb (182 kg)
CAPACITIES
Fuel (reserve included) 4.75 gal (18 litres)
Fuel reserve 1.32 gal (5 litres)
Engine oil Oil and oil filter change 0.47 gal (1.78 litres)
3 3
Front fork fluid 24.40 ± 0.15 ft (400 ± 2.5 cm ) (each leg)
Seats 2
Vehicle max. load 396.83 gal (180 Kg) (driver + passenger + luggage)
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GENERAL TECHNICAL INFORMATION
BREVA 750
2-6
GENERAL TECHNICAL INFORMATION
BREVA 750
1 = check and clean, adjust, lubricate or replace if necessary (as specified in the Service Manual);
2 = clean;
3 = replace;
4 = adjust.
IMPORTANT Perform maintenance operations at double the prescribed frequency if the vehicle is often used in rainy or very dusty
conditions, on unpaved roads, or in any kind of competition.
2-7
GENERAL TECHNICAL INFORMATION
BREVA 750
2-8
GENERAL TECHNICAL INFORMATION
BREVA 750
TIGHTENING
DESIGNATION
TORQUES (ftlb)
CYLINDER HEADS
2-9
GENERAL TECHNICAL INFORMATION
BREVA 750
GEARBOX
2 - 10
GENERAL TECHNICAL INFORMATION
BREVA 750
2 - 11
GENERAL TECHNICAL INFORMATION
BREVA 750
Key:
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GENERAL TECHNICAL INFORMATION
BREVA 750
Key:
1) Front light
2) Front fairing
3) Left rear-view mirror
4) Fuel tank cap
5) Fuel tank
6) Left side fairing
7) Main fuse carrier (30A)
8) Battery
9) Rider/Passenger seat
10) Passenger grab rail
11) Toolkit compartment
12) Left-hand rear shock absorber
13) Saddle lock
14) Left-hand passenger footpeg
15) Swing arm
16) Side stand
17) Rider left footpeg
18) Gear shift lever
19) Engine oil dipstick
2 - 13
GENERAL TECHNICAL INFORMATION
BREVA 750
Key:
1) Rear light
2) Glove compartment
3) Disc lock compartment
4) Rear brake fluid reservoir
5) Secondary fuse carrier
6) Right side fairing
7) Horn
8) Right rear-view mirror
9) Front brake fluid reservoir
10) Air cleaner
11) Engine oil filter
12) Rear brake lever
13) Engine Control Unit
14) Rider right footpeg
15) Driveshaft transmission
16) Rear brake master cylinder
17) Pillion right footpeg
18) Right-hand rear shock absorber
2 - 14
GENERAL TECHNICAL INFORMATION
BREVA 750
Legend:
1) Clutch lever
2) Ignition switch / steering lock ( - - )
3) Instruments and indicators
4) Front brake lever
5) Throttle handgrip
6) High beam flasher button ( )
7) Light dimmer ( - )
8) Cold start lever ( )
9) Directional indicator switch ( )
10)Horn button ( )
11)Engine stop switch ( - )
12)Start button ( )
Legend:
1) Green direction indicator LED ( )
2) Blue high beam LED ( )
3) Red engine oil pressure LED ( )
4) Amber fuel reserve warning LED ( )
5) Red “ ”LED
6) Green neutral indicator LED (N)
7) Tachometer
8) Red emergency flashers button ( )
9) TRIP button (multifunction display)
10)Multifunction digital display
11)Speedometer
2 - 15
GENERAL TECHNICAL INFORMATION
BREVA 750
2 - 16
GENERAL TECHNICAL INFORMATION
BREVA 750
Key:
1) Front brake disk.
2) Front calliper.
3) Front oil pipe.
4) Front brake master cylinder with lever and reservoir.
5) Rear brake lever (left side).
6) Rear brake master cylinder (left side).
7) Rear brake oil reservoir.
8) rear oil pipes.
9) Rear brake disk (right side).
10) Rear caliper.
2 - 17
GENERAL TECHNICAL INFORMATION
BREVA 750
2 - 18
GENERAL TECHNICAL INFORMATION
BREVA 750
2 - 19
GENERAL TECHNICAL INFORMATION
BREVA 750
EXHAUST SYSTEM
2 - 20
GENERAL TECHNICAL INFORMATION
BREVA 750
2 - 21
GENERAL TECHNICAL INFORMATION
BREVA
2 - 22
GENERAL TECHNICAL INFORMATION
BREVA
2 - 23
GENERAL TECHNICAL INFORMATION
BREVA
10
2 - 24
GENERAL TECHNICAL INFORMATION
BREVA
11
12
13
14 Muffler stamping.
2 - 25
GENERAL TECHNICAL INFORMATION
BREVA
2 - 26
FUEL SYSTEM
BREVA 750
FUEL SYSTEM 3
3-1
FUEL SYSTEM
BREVA 750
TABLE OF CONTENTS
3.1. FUEL SYSTEM ...........................................................................................................................................3
3.1.1. FUEL SYSTEM LAYOUT .........................................................................................................................3
3.1.2. INJECTION SYSTEM LAYOUT................................................................................................................4
3.1.3. CYLINDER TIMING .................................................................................................................................6
3.1.4. SETTING THE CO RATE.........................................................................................................................8
3.1.5. AXONE ...................................................................................................................................................9
3.1.6. INTAKE MANIFOLDS ............................................................................................................................16
3-2
FUEL SYSTEM
BREVA 750
Key:
1. Fuel tank
2. Throttle body
3. Drain hoses
4. Fuel filter
5. Fuel delivery pipe
6. Fuel pump assembly
7. Level check thermistor
3-3
FUEL SYSTEM
BREVA 750
3-4
FUEL SYSTEM
BREVA 750
Key:
1. Engine control unit
2. Ignition switch
3. Battery
4. Fuel pump
5. Coils
6. Dashboard
7. Air temperature sensor
8. Throttle valve position sensor
9. Injectors
10. Crankshaft position sensor
11. Engine temperature sensor
12. Lambda Sensor
13. Bank angle sensor
3-5
FUEL SYSTEM
BREVA 750
3-6
FUEL SYSTEM
BREVA 750
3-7
FUEL SYSTEM
BREVA 750
3-8
FUEL SYSTEM
BREVA 750
3.1.5. AXONE
3-9
FUEL SYSTEM
BREVA 750
3 - 10
FUEL SYSTEM
BREVA 750
3 - 11
FUEL SYSTEM
BREVA 750
3 - 12
FUEL SYSTEM
BREVA 750
3 - 13
FUEL SYSTEM
BREVA 750
Microprocessor
Signal panel (detects errors on the engine speed/timing sen-
sor)
• Active diagnostics page.
3 - 14
FUEL SYSTEM
BREVA 750
3 - 15
FUEL SYSTEM
BREVA 750
3 - 16
FUEL SYSTEM
BREVA 750
3 - 17
ENGINE
BREVA 750
ENGINE 4
4-1
ENGINE
BREVA 750
TABLE OF CONTENTS
4.1. DROPPING AND REFITTING THE ENGINE................................................................................................4
4.1.1. DROPPING THE ENGINE FROM THE FRAME........................................................................................4
4.1.2. REFITTING THE ENGINE IN THE FRAME.............................................................................................12
4.1.3. DISASSEMBLING THE GEARBOX FROM THE ENGINE .......................................................................19
4.1.4. REMOVING THE STARTER MOTOR.....................................................................................................20
4.1.5. REMOVING THE OIL INTAKE PIPE FROM THE CRANKCASE..............................................................21
4.1.6. TIGHTENING TORQUES.......................................................................................................................22
4.2. CYLINDER HEAD COVERS......................................................................................................................23
4.2.1. CYLINDER HEAD COVERS REMOVAL.................................................................................................23
4.2.2. INSPECTION.........................................................................................................................................24
4.2.3. REASSEMBLY ......................................................................................................................................25
4.2.4. TIGHTENING TORQUES.......................................................................................................................26
4.3. TIMING.....................................................................................................................................................27
4.3.1. REMOVING THE FRONT ENGINE COVER ...........................................................................................27
4.3.2. DISASSEMBLING THE ALTERNATOR..................................................................................................28
4.3.3. REMOVING THE TIMING/RPM SENSOR ..............................................................................................30
4.3.4. REMOVING THE TIMING UNIT COVER ................................................................................................31
4.3.5. TIMING UNIT INSPECTION...................................................................................................................33
4.3.6. REASSEMBLING THE TIMING UNIT.....................................................................................................36
4.3.7. TIMING CHECK.....................................................................................................................................39
4.3.8. ASSEMBLING THE PHONIC WHEEL ....................................................................................................41
4.3.9. CHECKING THE AIR GAP AND REASSEMBLING THE SENSOR..........................................................42
4.3.10. REASSEMBLING THE ALTERNATOR ...............................................................................................44
4.3.11. TIMING DATA....................................................................................................................................46
4.3.12. TIGHTENING TORQUES ...................................................................................................................47
4.4. CLUTCH...................................................................................................................................................48
4.4.1. DISASSEMBLING THE CLUTCH PLATE AND DISK ..............................................................................48
4.4.2. INSPECTION.........................................................................................................................................49
4.4.3. ASSEMBLING THE CLUTCH PLATE AND DISK....................................................................................50
4.4.4. TIGHTENING TORQUES.......................................................................................................................52
4.5. ENGINE PRESSURE PLATE FLYWHEEL.................................................................................................53
4.5.1. DISASSEMBLING THE FLYWHEEL ......................................................................................................53
4.5.2. INSPECTION.........................................................................................................................................54
4.5.3. REASSEMBLING THE PRESSURE PLATE FLYWHEEL........................................................................55
4.5.4. TIGHTENING TORQUES.......................................................................................................................57
4.6. CYLINDER HEADS...................................................................................................................................58
4.6.1. DISASSEMBLING THE CYLINDER HEADS...........................................................................................58
4.6.2. DISASSEMBLING THE VALVES FROM THE CYLINDER HEADS..........................................................60
4.6.3. DISASSEMBLING THE VALVE GUIDE FROM THE CYLINDER HEAD...................................................62
4.6.4. REASSEMBLING AND CHECKING THE VALVE SEATS........................................................................63
4.6.5. RE-CUTTING THE VALVE SEATS.........................................................................................................65
4.6.6. SPRING PACK INSPECTION ................................................................................................................68
4.6.7. REASSEMBLING THE CYLINDER HEADS............................................................................................70
4.6.8. TIGHTENING TORQUES.......................................................................................................................72
4.7. CYLINDERS .............................................................................................................................................73
4.7.1. DISASSEMBLING THE CYLINDERS .....................................................................................................73
4.7.2. INSPECTION.........................................................................................................................................74
4.7.3. ASSEMBLING THE CYLINDERS...........................................................................................................75
4.7.4. TIGHTENING TORQUES.......................................................................................................................77
4.8. PISTONS..................................................................................................................................................78
4.8.1. DISASSEMBLING THE PISTONS..........................................................................................................78
4.8.2. INSPECTION.........................................................................................................................................79
4.8.3. REASSEMBLING THE PISTONS...........................................................................................................81
4.9. PISTON RINGS AND OIL CONTROL RING...............................................................................................83
4.9.1. DISASSEMBLY .....................................................................................................................................83
4.9.2. PISTON RINGS INSPECTION ...............................................................................................................84
4.9.3. REASSEMBLING THE PISTON RINGS AND OIL CONTROL RING........................................................85
4.10. CRANKCASE............................................................................................................................................86
4.10.1. DISASSEMBLING THE CRANKCASE ................................................................................................86
4.10.2. INSPECTION .....................................................................................................................................89
4.10.3. REASSEMBLING THE CRANKCASE .................................................................................................90
4.10.4. TIGHTENING TORQUES ...................................................................................................................94
4.11. CONNECTING RODS...............................................................................................................................95
4.11.1. DISASSEMBLING THE CONNECTING RODS....................................................................................95
4.11.2. CONNECTING ROD CLEARANCE.....................................................................................................96
4.11.3. REASSEMBLING THE CONNECTING RODS.....................................................................................97
4.11.4. TIGHTENING TORQUES ...................................................................................................................98
4.12. CRANKSHAFT..........................................................................................................................................99
4-2
ENGINE
BREVA 750
4-3
ENGINE
BREVA 750
4-4
ENGINE
BREVA 750
4-5
ENGINE
BREVA 750
4-6
ENGINE
BREVA 750
4-7
ENGINE
BREVA 750
• Open the clamp and detach the airbox oil breather tube.
4-8
ENGINE
BREVA 750
• Unscrew the screw that secures the earth lead lug to the
engine block.
4-9
ENGINE
BREVA 750
4 - 10
ENGINE
BREVA 750
4 - 11
ENGINE
BREVA 750
• Fit the upper screws that secure the frame to the gear-
box cover and torque to the prescribed value.
4 - 12
ENGINE
BREVA 750
• Fit the screw responsible for securing the earth lead lug
to the engine block.
• Insert the oil breather pipe into the airbox and secure it
with the specific clamp.
4 - 13
ENGINE
BREVA 750
4 - 14
ENGINE
BREVA 750
• Fit the injectors into their seats and assemble the re-
tainer, tightening the screw to the prescribed torque
value.
4 - 15
ENGINE
BREVA 750
• Position the clutch linkage and fit the spindle to the en-
gine block, fixing with the relative cotter.
4 - 16
ENGINE
BREVA 750
• Fit the rpm sensor and torque the screws to the pre-
scribed value.
4 - 17
ENGINE
BREVA 750
• Position the right hand foot peg bracket together with the
brake caliper.
• Fit the brake light switch to its support.
4 - 18
ENGINE
BREVA
4 - 19
ENGINE
BREVA 750
4 - 20
ENGINE
BREVA
4 - 21
ENGINE
BREVA 750
ELECTRIC STARTING
Starter motor fixing screws 0,780555555555556 ftlb
4 - 22
ENGINE
BREVA 750
4 - 23
ENGINE
BREVA 750
4.2.2. INSPECTION
• Check that the head cover contact surfaces are not
damaged and that there are no blowholes
4 - 24
ENGINE
BREVA 750
4.2.3. REASSEMBLY
• Replace the cover gaskets and refit the covers to the
cylinder heads
4 - 25
ENGINE
BREVA 750
CYLINDER HEADS
Cylinder head covers fixing screws 0,318055555555556 ftlb
Spark plugs 0,780555555555556 ftlb
4 - 26
ENGINE
BREVA 750
4.3. TIMING
4.3.1. REMOVING THE FRONT ENGINE COVER
• Undo the fixing screws and remove the alternator unit
covers
4 - 27
ENGINE
BREVA 750
4 - 28
ENGINE
BREVA 750
4 - 29
ENGINE
BREVA 750
4 - 30
ENGINE
BREVA 750
4 - 31
ENGINE
BREVA 750
• Remove the two screws and timing gear from the shaft,
together with the chain and oil pump gear.
4 - 32
ENGINE
BREVA 750
4 - 33
ENGINE
BREVA 750
4 - 34
ENGINE
BREVA 750
• Check that the rocker control rods are straight, and that
the end contact surfaces show no signs of seizure, oth-
erwise replace them.
• To check that the pressed ends on the rods are free of
clearance, allow the rods to fall onto a flat surface from a
small height. If the rods emit a high, sharp sound on im-
pact, the ends are without play.
4 - 35
ENGINE
BREVA 750
• Fit the two gears with the timing belt and check the po-
sition of the reference marks. Tighten the screws with a
torque wrench to the specified torque.
4 - 36
ENGINE
BREVA 750
• Screw the oil pump nut while holding the oil pump shaft
itself immobile.
4 - 37
ENGINE
BREVA 750
4 - 38
ENGINE
BREVA 750
4 - 39
ENGINE
BREVA 750
• Turn clockwise until the rod and rockers come into con-
tact and check the intake valve opening advance rela-
tive to the top dead centre.
• Continue turning until the rod is again free and read the
value of the closing delay relative to the bottom dead
centre.
4 - 40
ENGINE
BREVA 750
• Fit the gasket and timing unit cover, and tighten to the
specified torque with a torque wrench.
4 - 41
ENGINE
BREVA 750
4 - 42
ENGINE
BREVA 750
4 - 43
ENGINE
BREVA 750
4 - 44
ENGINE
BREVA 750
• Fit the stator and its cover and screw in the three re-
taining screws.
4 - 45
ENGINE
BREVA 750
Exhaust:
- opens 53° before B.D.C.;
- closes 15° after T.D.C.
4 - 46
ENGINE
BREVA 750
TIMING UNIT
Camshaft to crankcase fixing connection 0,925694444444444 ftlb
Timing gear to camshaft fixing screws 0,780555555555556 ftlb
Phonic wheel fixing screws 0,780555555555556 ftlb
4 - 47
ENGINE
BREVA 750
4.4. CLUTCH
4.4.1. DISASSEMBLING THE CLUTCH PLATE AND
DISK
• Fit the engine flywheel locking tool to the crankcase.
4 - 48
ENGINE
BREVA 750
4.4.2. INSPECTION
• Check that the clutch disk is not scored or heavily
worn.
• Check the wear of the gear teeth and clutch disk con-
tact surface.
4 - 49
ENGINE
BREVA 750
• Fit the clutch disk centring tool to the plate and seat the
disk.
4 - 50
ENGINE
BREVA 750
4 - 51
ENGINE
BREVA 750
CLUTCH
Clutch shaft fixing nut 73.76 ftlb
4 - 52
ENGINE
BREVA 750
4 - 53
ENGINE
BREVA 750
4.5.2. INSPECTION
• Check that the flywheel is not scored on the disk con-
tact surface.
• Check that the crankshaft seating is not deformed, oth-
erwise replace the flywheel.
4 - 54
ENGINE
BREVA 750
4 - 55
ENGINE
BREVA 750
4 - 56
ENGINE
BREVA 750
4 - 57
ENGINE
BREVA 750
4 - 58
ENGINE
BREVA 750
4 - 59
ENGINE
BREVA 750
4 - 60
ENGINE
BREVA 750
• Extract the upper cup, the spring and the valve itself.
4 - 61
ENGINE
BREVA 750
4 - 62
ENGINE
BREVA 750
• Once the valve guides are seated, ream its internal di-
ameter to the value given in the table.
4 - 63
ENGINE
BREVA 750
INTAKE
B (theoreti- C (theoreti-
Aø D
cal) ø cal)
in (mm) in (mm)
in (mm) in (mm)
1.2598÷1.2596 0.0559 0.0393
1.3385 (34)
(32.0÷32.25) (1.42) (1)
EXHAUST
B (theoreti- C (theoreti-
Aø D
cal) ø cal)
in (mm) in (mm)
in (mm) in (mm)
1.0913÷1.1011 0.0448
1.1810 (30) 0.0629 (1.6)
(27.72÷27.97) (1.14)
4 - 64
ENGINE
BREVA 750
4 - 65
ENGINE
BREVA 750
4 - 66
ENGINE
BREVA 750
4 - 67
ENGINE
BREVA 750
Free length
4 - 68
ENGINE
BREVA 750
SPRING CHARACTERISTICS
4 - 69
ENGINE
BREVA 750
4 - 70
ENGINE
BREVA 750
4 - 71
ENGINE
BREVA 750
CYLINDER HEADS
Cylinder head covers fixing screws 0,318055555555556 ftlb
Spark plugs 0,780555555555556 ftlb
4 - 72
ENGINE
BREVA 750
4.7. CYLINDERS
4.7.1. DISASSEMBLING THE CYLINDERS
• Remove the cylinders and gaskets from the stud bolts.
4 - 73
ENGINE
BREVA 750
4.7.2. INSPECTION
• First check for superficial scoring and then check wear
of the cylinder bore surfaces using a dial gauge.
• Measure the inside diameter of the cylinder bore at
three different heights, then turn the dial gauge through
90° and repeat the measurements; the dial gauge must
be first zero set on a ring gauge.
Key:
1) 1st measurement
2) 2nd measurement
3) 3rd measurement
4) control dimension for selection
Cylinder diameter selection
4 - 74
ENGINE
BREVA 750
4 - 75
ENGINE
BREVA 750
4 - 76
ENGINE
BREVA 750
4 - 77
ENGINE
BREVA 750
4.8. PISTONS
4.8.1. DISASSEMBLING THE PISTONS
• Protect the cylinder seat and remove the two gudgeon
pin clips.
4 - 78
ENGINE
BREVA 750
4.8.2. INSPECTION
• First check for superficial scoring and then check wear
of the cylinder bore surfaces using a dial gauge.
• Measure the inside diameter of the cylinder bore at
three different heights then turn the dial gauge through
90° and repeat the measurements; the dial gauge must
be first zero set on a ring gauge.
Key:
1) 1st measurement
2) 2nd measurement
3) 3rd measurement
4) control dimension for selection
• Check the piston diameter at the specified height and
on an axis perpendicular to the gudgeon pin.
• Selection values refer to the bare piston (without
graphite facing).
4 - 79
ENGINE
BREVA 750
4 - 80
ENGINE
BREVA 750
4 - 81
ENGINE
BREVA 750
4 - 82
ENGINE
BREVA 750
4 - 83
ENGINE
BREVA 750
4 - 84
ENGINE
BREVA 750
4 - 85
ENGINE
BREVA 750
4.10. CRANKCASE
4.10.1. DISASSEMBLING THE CRANKCASE
• Unscrew the four internal crankcase nuts and the six
external ones.
• Fit a rod into the seat of the tie rod securing the engine
to the frame and lightly knock it with a plastic mallet to
separate the two halves of the crankcase.
4 - 86
ENGINE
BREVA 750
4 - 87
ENGINE
BREVA 750
4 - 88
ENGINE
BREVA 750
4.10.2. INSPECTION
• Check that the contact surfaces are in good condition
and not scored or dented. Remove the liquid seal resi-
due with trichloroethylene.
4 - 89
ENGINE
BREVA 750
• Fit the timing shaft into its seat in the upper crankcase
half; lubricate, fit and secure the timing shaft retainer
bushing.
• Fit the timing side and flywheel side half shells to the
upper crankcase half together with their thrust washers.
Lubricate all parts before installing them.
4 - 90
ENGINE
BREVA 750
• Lubricate and fit the seal ring to the engine shaft and
mount the assembly to the crankcase, taking care to
seat the connecting rods correctly.
4 - 91
ENGINE
BREVA 750
4 - 92
ENGINE
BREVA 750
4 - 93
ENGINE
BREVA 750
4 - 94
ENGINE
BREVA 750
4 - 95
ENGINE
BREVA 750
NORMAL (production)
A B
in (mm) in (mm)
0.0605÷0.0607 0.0601÷0.0603
(1.537÷1.543) (1.527÷1.533)
Diameter of bush driven into connecting rod small end and gudgeon pin
INSIDE DIAMETER FOR BUSH- DIAMETER OF GUDGEON PIN SMALL END BUSHING TO GUD-
ING DRIVEN INTO CONNECTING in (mm) GEON PIN ASSEMBLY CLEAR-
ROD SMALL END ANCE
in (mm) in (mm)
0.7090÷0.7094 0.7085÷0.7086 0.00039÷0.00094
(18.010÷18.020) (17.996÷18.000) (0.010÷0.024)
4 - 96
ENGINE
BREVA 750
4 - 97
ENGINE
BREVA 750
4 - 98
ENGINE
BREVA 750
4.12. CRANKSHAFT
4.12.1. DISASSEMBLING THE CRANKSHAFT
• Remove the connecting rods from the crankshaft.
• Undo the oil cap and carefully clean the oil ducts lead-
ing to the connecting rods and main journals.
4 - 99
ENGINE
BREVA 750
Normal (production) in mm
1.5757÷1.6931 (40.023÷43.007)
Normal (production) in mm
1.8555÷1.8559 (47.130÷47.142)
Normal (production) in mm
0.0804÷0.0807 (2.044÷2.050)
Normal (production) in mm
0.00027÷0.00185 (0.007÷0.047)
4 - 100
ENGINE
BREVA 750
4 - 101
ENGINE
BREVA 750
4 - 102
ENGINE
BREVA 750
• Flatten out the locking tab and remove the mesh filter
retainer screw and mesh filter itself from the sump.
4 - 103
ENGINE
BREVA 750
4 - 104
ENGINE
BREVA 750
4 - 105
ENGINE
BREVA 750
4.13.3. REASSEMBLY
• Fit the filter, locking tab and fixing screw and tighten
down.
4 - 106
ENGINE
BREVA 750
• Fit the filter cartridge and tighten its screw to the speci-
fied torque.
4 - 107
ENGINE
BREVA 750
4 - 108
ENGINE
BREVA 750
4 - 109
ENGINE
BREVA 750
EXTERNAL ROTOR
Check that the internal and external surfaces and the faces
are not scored or damaged, otherwise renew both rotors.
External rotor data:
- external ø 1.5960÷1.5972 in (40.540÷40.570 mm);
- internal ø 0.9529÷0.9539 in (24.205÷24.230 mm);
- thickness 0.7464÷0.7476 in (18.960÷18.990 mm).
4 - 110
ENGINE
BREVA 750
INTERNAL ROTOR
Check that the internal and external surfaces and the faces
are not scored or damaged, otherwise renew both rotors.
Internal rotor data:
- external ø 1.1710÷1.1720 in (29.745÷29.770 mm);
- ø of bore for pump drive shaft 0.4724÷0.4731 in
(12.000÷12.018 mm);
- thickness 0.7464÷0.7476 in (18.960÷18.990 mm).
ROLLER BEARINGS
Check that the bearing rollers are not damaged, otherwise
renew the bearings.
ASSEMBLY CLEARANCES
- between pump body and external rotor
0.00314÷0.00531 in (0.080÷0.135 mm);
- between bore on internal rotor and pump drive shaft
0.00062÷0.00240 in (0.016÷0.061 mm);
- between bore on pump body and pump drive shaft
0.00062÷0.00240 in (0.016÷0.061 mm).
4 - 111
ENGINE
BREVA 750
4 - 112
ENGINE
BREVA 750
4 - 113
ENGINE
BREVA 750
4 - 114
ENGINE
BREVA 750
4 - 115
ENGINE
BREVA 750
LUBRICATION
Engine oil pressure sensor 8.90÷7.38 ftlb
Oil pump to crankcase fixing screws 0,318055555555556 ftlb
Filter cartridge sealing cover fixing screw 0,780555555555556 ftlb
4 - 116
GEARBOX
BREVA 750
GEARBOX 5
5-1
GEARBOX
BREVA 750
TABLE OF CONTENTS
5.1. GEARBOX..................................................................................................................................................3
5.1.1. DISASSEMBLY .......................................................................................................................................3
5.1.2. REASSEMBLY ........................................................................................................................................7
5.1.3. TIGHTENING TORQUES.......................................................................................................................11
5.2. CLUTCH HOUSING ..................................................................................................................................12
5.2.1. DISASSEMBLY .....................................................................................................................................12
5.2.2. REASSEMBLY ......................................................................................................................................15
5.2.3. TIGHTENING TORQUES.......................................................................................................................19
5.3. TRANSMISSION.......................................................................................................................................20
5.3.1. TRANSMISSION GEARS.......................................................................................................................20
5-2
GEARBOX
BREVA 750
5.1. GEARBOX
5.1.1. DISASSEMBLY
• Fit the clutch shaft to the gearbox in such a way that the
gear itself meshes with the primary shaft gear.
5-3
GEARBOX
BREVA 750
5-4
GEARBOX
BREVA 750
5-5
GEARBOX
BREVA 750
5-6
GEARBOX
BREVA 750
5.1.2. REASSEMBLY
REASSEMBLING THE PRESELECTOR
• After having refitted the entire gearing assembly includ-
ing shafts to the gearbox cover, fit the spring and its two
extensions over the preselector pawl, making sure that
the spacing between the spring extensions is the same
on the pawl as between their free extremities.
5-7
GEARBOX
BREVA 750
• Fit the preselector to the cover, making sure that the two
spring extensions fit into the concavity in the adjuster
screw. Turn the screw by 90° and tighten down the lock
nut.
5-8
GEARBOX
BREVA 750
• Fit the gear and washer to the primary shaft and tighten
the fixing nut to the specified torque and snug it in with a
punch.
5-9
GEARBOX
BREVA 750
5 - 10
GEARBOX
BREVA 750
GEARBOX
Primary shaft fixing nuts 47.94 ftlb
Cover to gearbox fixing screws 0,318055555555556 ftlb
Gearbox to clutch housing cover fixing screws 0,318055555555556 ftlb
Index lever fixing nut 0,195833333333333 ftlb
5 - 11
GEARBOX
BREVA 750
5 - 12
GEARBOX
BREVA 750
5 - 13
GEARBOX
BREVA 750
5 - 14
GEARBOX
BREVA 750
5.2.2. REASSEMBLY
• Refit the clutch shaft by lightly tapping with a plastic mal-
let, refit the circlip and seal ring.
5 - 15
GEARBOX
BREVA 750
• Fit the clutch housing gasket and locate the housing it-
self.
5 - 16
GEARBOX
BREVA 750
• Screw in the clutch shaft nut with the provided tool and
snug it in with a punch.
5 - 17
GEARBOX
BREVA 750
• Fit the clutch control rod to the shaft with its larger end
oriented towards the control lever.
5 - 18
GEARBOX
BREVA 750
CLUTCH
Clutch shaft fixing nut 73.76 ftlb
5 - 19
GEARBOX
BREVA 750
5.3. TRANSMISSION
5.3.1. TRANSMISSION GEARS
5 - 20
TRANSMISSION
BREVA 750
TRANSMISSION 6
6-1
TRANSMISSION
BREVA 750
TABLE OF CONTENTS
6.1. DISASSEMBLING THE SWING ARM ..........................................................................................................3
6.1.1. DISASSEMBLING THE SWING ARM COMPLETE WITH TRANSMISSION CASE ....................................3
6.1.2. INSPECTION...........................................................................................................................................5
6.1.3. REASSEMBLING THE SWING ARM........................................................................................................6
6.1.4. TIGHTENING TORQUES.........................................................................................................................9
6.2. TRANSMISSION CASE.............................................................................................................................10
6.2.1. DISASSEMBLING THE PINION HOUSING ............................................................................................10
6.2.2. INSPECTION.........................................................................................................................................12
6.2.3. REASSEMBLING THE PINION HOUSING .............................................................................................13
6.2.4. TIGHTENING TORQUES.......................................................................................................................16
6.3. DISASSEMBLING THE TRANSMISSION CASE........................................................................................17
6.3.1. DISASSEMBLING THE TRANSMISSION CASE.....................................................................................17
6.3.2. INSPECTION.........................................................................................................................................20
6.3.3. PINION – GEAR MESHING (BEVEL GEAR SET)...................................................................................21
6.3.4. REASSEMBLING THE TRANSMISSION CASE......................................................................................24
6.3.5. TIGHTENING TORQUES.......................................................................................................................28
6.4. SWING ARM.............................................................................................................................................29
6.4.1. DISASSEMBLING THE SWING ARM.....................................................................................................29
6.4.2. INSPECTION.........................................................................................................................................30
6.5. REASSEMBLING THE SWING ARM .........................................................................................................31
6.5.1. TIGHTENING TORQUES.......................................................................................................................32
6-2
TRANSMISSION
BREVA 750
6-3
TRANSMISSION
BREVA 750
6-4
TRANSMISSION
BREVA 750
6.1.2. INSPECTION
• Check that the cardan coupling is in good condition, that
the gear teeth that mesh with the sleeve splines and the
coupling splines are not damaged or excessively worn;
otherwise, renew the coupling.
• Check that the rubber boot is not cut or pierced, renew if
necessary.
• Check that the threads of the swing arm fixing pins and
nuts are in good condition and not stripped; renew if
necessary.
• Check that the sleeve splines are in good condition and
undamaged; renew if necessary.
• Check that the spring is not distorted; renew if neces-
sary.
• Check that the circlip has not lost its elasticity and is not
distorted.
• Check that the external teeth and internal splines of the
sleeve are undamaged.
6-5
TRANSMISSION
BREVA 750
6-6
TRANSMISSION
BREVA 750
• Fit the spacer and wheel axle and tighten the nuts fully
working in crosswise sequence.
• Fit the dust cover with internal circlip in the front of the
swing arm.
• Tighten the jubilee clamp.
• Fit the spring in the relative bore in the cardan coupling
and apply grease to hold it in position.
6-7
TRANSMISSION
BREVA 750
• Fit the nuts onto the studs and tighten them fully down.
6-8
TRANSMISSION
BREVA 750
6-9
TRANSMISSION
BREVA 750
• Insert the splined shaft of the pinion in the tool and un-
screw the nut.
6 - 10
TRANSMISSION
BREVA 750
6 - 11
TRANSMISSION
BREVA 750
6.2.2. INSPECTION
• Check that the pinion teeth are in good condition, not
excessively worn and undamaged; if necessary renew
the bevel gear set.
• Check that the two taper roller bearings are in good
condition, that the rollers are undamaged and not ex-
cessively worn; renew if necessary.
• Check that the clearance washers are not distorted or
chipped; renew if necessary.
• Check that the seal rings are compact, undamaged, and
not excessively worn; renew if necessary.
6 - 12
TRANSMISSION
BREVA 750
6 - 13
TRANSMISSION
BREVA 750
6 - 14
TRANSMISSION
BREVA 750
6 - 15
TRANSMISSION
BREVA 750
REAR TRANSMISSION
Bevel pinion to case fixing nut 73.76 ftlb
Bevel gear to hollow shaft fixing screws 30.98 ftlb
Cover to transmission case fixing screws 0,780555555555556 ftlb
6 - 16
TRANSMISSION
BREVA 750
6 - 17
TRANSMISSION
BREVA 750
6 - 18
TRANSMISSION
BREVA 750
6 - 19
TRANSMISSION
BREVA 750
6.3.2. INSPECTION
• Check that the fins of the hollow shaft subject to the ac-
tion of the torque dampers are not damaged; check that
the contact surfaces of: the seal ring, the bearing on the
cover, the outer race of the bearing on the transmission
case, the circlip groove on the hollow shaft: are not ex-
cessively worn, damaged, or pitted, otherwise renew the
parts.
• Check that the seal ring on the case is compact and has
not suffered a reduction of its elastic properties, other-
wise renew.
• Check that the roller bearing on the transmission case
shows no signs of out of round or worn rollers, other-
wise, renew the bearing.
• Check that all the components are in perfect working
order and that the mating surfaces of transmission case
and cover are not scored or damaged.
6 - 20
TRANSMISSION
BREVA 750
6 - 21
TRANSMISSION
BREVA 750
Turn the pinion in the drive direction while braking the gear
so that the rotation takes place under load and the contact
areas are marked on the pinion tooth surfaces.
6 - 22
TRANSMISSION
BREVA 750
6 - 23
TRANSMISSION
BREVA 750
6 - 24
TRANSMISSION
BREVA 750
6 - 25
TRANSMISSION
BREVA 750
6 - 26
TRANSMISSION
BREVA 750
• Fit the brake disk to the hollow shaft and use a torque
wrench to tighten the screws complete with washers.
6 - 27
TRANSMISSION
BREVA 750
REAR TRANSMISSION
Bevel pinion to case fixing nut 73.76 ftlb
Bevel gear to hollow shaft fixing screws 30.98 ftlb
Cover to transmission case fixing screws 0,780555555555556 ftlb
6 - 28
TRANSMISSION
BREVA 750
• Loosen the pins so that you can separate the swing arm
from the transmission case.
• Remove the shimming washer from between the right
arm of the swing arm assy. and the transmission case.
6 - 29
TRANSMISSION
BREVA 750
6.4.2. INSPECTION
• Check that the arms of the swing arm assy show no signs of cracking or distortion; otherwise, if possible, true up
the swing arm assy, observing the measurements shown in the drawing.
in (mm)
A 18.0314 ± 0.0039 (458 ± 0.1)
B 0.7873 (20)
C 1.2519 (31.8)
D 0.8661 – 0.8681
(Ø 22.000 – 22.052)
E 1.8503 (47)
F 1.8503 (47)
G 6.0629 (154)
H 1.1810 (30)
L 5.5511 (141)
M 3.4566 (87.8)
6 - 30
TRANSMISSION
BREVA 750
6 - 31
TRANSMISSION
BREVA 750
6 - 32
CYCLE PARTS
BREVA 750
CYCLE PARTS 7
7-1
CYCLE PARTS
BREVA 750
TABLE OF CONTENTS
7.1. FRONT FORK.............................................................................................................................................3
7.1.1. DIAGRAM ...............................................................................................................................................3
7.1.2. FORK LEG REMOVAL.............................................................................................................................4
7.1.3. GENERAL PRESCRIPTIONS FOR A CORRECT OVERHAUL .................................................................6
7.1.4. TROUBLESHOOTING .............................................................................................................................7
7.1.5. FRONT FORK OIL CHANGE ...................................................................................................................8
7.1.6. FORK LEG DISASSEMBLY AND OVERHAUL .......................................................................................11
7.1.7. INSPECTION.........................................................................................................................................13
7.1.8. REASSEMBLING THE FRONT FORK....................................................................................................14
7.1.9. FORK LEG REASSEMBLY ....................................................................................................................17
7.1.10. TIGHTENING TORQUES ...................................................................................................................18
7.2. ADJUSTING CLEARANCE IN THE BEARINGS.........................................................................................19
7.2.1. ADJUSTING CLEARANCE IN THE STEERING BEARINGS ...................................................................19
7.2.2. TIGHTENING TORQUES.......................................................................................................................20
7.3. REAR SUSPENSION................................................................................................................................21
7.3.1. DISASSEMBLING THE REAR SUSPENSION ........................................................................................21
7.3.2. INSPECTION.........................................................................................................................................22
7.3.3. REASSEMBLING THE REAR SUSPENSION.........................................................................................23
7.3.4. TIGHTENING TORQUES.......................................................................................................................24
7-2
CYCLE PARTS
BREVA 750
Key:
7-3
CYCLE PARTS
BREVA 750
WARNING
During the following procedures, the legs and their in-
ternal components must be locked in a vice. Take great
care not to damage them by overtightening; always use
aluminum jaw coverings.
7-4
CYCLE PARTS
BREVA 750
7-5
CYCLE PARTS
BREVA 750
7-6
CYCLE PARTS
BREVA 750
7.1.4. TROUBLESHOOTING
The following paragraph lists some potential problems with
the fork and their causes complete with suggested solutions.
Always refer to this table before working on the fork.
PROBLEM CAUSE SOLUTION
Oil leak from oil seal ring 1. Worn seal ring 1. Replace the seal ring
2. Scored stanchion 2. Replace stanchion and ring
3. The ring is dirty 3. Clean or replace
Oil leakage from the bottom 1. Defective foot gasket 1. Replace gasket
2. The foot screw is loose 2. Tighten screw
The fork is too 1. Low oil level 1. Restore correct fork oil level
soft 2. Defective spring 2. Replace spring
3. Oil viscosity too low 3. Change oil with oil of correct viscosity
The fork is too 1. Oil level too high 1. Restore correct fork oil level
hard 2. Oil viscosity too high 2. Change oil with oil of correct viscosity
7-7
CYCLE PARTS
BREVA 750
7-8
CYCLE PARTS
BREVA 750
• Drain the oil contents from the interior of the fork leg.
To facilitate the drainage of oil from inside the plunger rod,
pump out the oil by repeatedly pushing the stanchion into the
slider.
• Check the fork leg carefully and make sure there are no
signs of damage.
• If no parts are damaged or particularly worn reassemble
the leg otherwise renew the damaged parts.
FILLING:
• Clamp the slider in a vice.
• Pour oil into the stanchion ensuring that it also fills the
internal passages of the plunger rod.
7-9
CYCLE PARTS
BREVA 750
7 - 10
CYCLE PARTS
BREVA 750
WARNING
Work carefully to avoid damaging the slider rim and the
wiper seal.
7 - 11
CYCLE PARTS
BREVA 750
WARNING
Be careful not to damage the slider rim.
7 - 12
CYCLE PARTS
BREVA 750
7.1.7. INSPECTION
• Check all the parts removed from inside the slider, spe-
cifically: the seal ring and the dust wiper seal since
these parts ensure the oiltight properties; these parts
must be renewed if damaged;
• Check the bushing on the stanchion; if damaged or
worn, remove and renew.
• Extract the plunger assembly from the stanchion tube;
renew the counter-spring and the plunger ring if dam-
aged.
7 - 13
CYCLE PARTS
BREVA 750
7 - 14
CYCLE PARTS
BREVA 750
• Slide the stanchion into the slider and push it fully home.
• Screw in the foot screw with its seal and tighten it to the
prescribed torque.
7 - 15
CYCLE PARTS
BREVA 750
7 - 16
CYCLE PARTS
BREVA 750
7 - 17
CYCLE PARTS
BREVA 750
FRONT SUSPENSION
Centre stand to frame fixing screws 0,318055555555556 ftlb
Stand locknut 0,925694444444444 ftlb
Fork head fixing screws 1,38819444444444 ftlb
Fork base fixing screws 1,38819444444444 ftlb
Slider to wheel spindle fixing screws 0,318055555555556 ftlb
7 - 18
CYCLE PARTS
BREVA 750
7 - 19
CYCLE PARTS
BREVA 750
STEERING
Steering head fixing screw 36.88 ftlb
7 - 20
CYCLE PARTS
BREVA 750
7 - 21
CYCLE PARTS
BREVA 750
7.3.2. INSPECTION
• Check the condition of the springs and the dampers (al-
ways inspect in pairs in order to ensure they present
identical preload to avoid unequal forces being exerted
on the rear swing arm and the transmission case); if
necessary, renew either the springs or the complete
suspension struts.
• Check the flexible bushes on the struts for possible deg-
radation or hardening and renew if necessary. If you no-
tice irregularities in the cushioning action of the damp-
ers, they must be renewed.
IMPORTANT To ensure good stability of the motorcycle,
both the suspension springs must be adjusted to the
same position.
7 - 22
CYCLE PARTS
BREVA 750
7 - 23
CYCLE PARTS
BREVA 750
REAR SUSPENSIONS
Rear suspension upper and lower sections fixing screws 0,635416666666667 ftlb
7 - 24
ELECTRICAL SYSTEM
BREVA 750
ELECTRICAL SYSTEM 8
8-1
ELECTRICAL SYSTEM
BREVA 750
TABLE OF CONTENTS
8.1. ELECTRICAL SYSTEM...............................................................................................................................3
8.1.1. COMPONENTS LAYOUT ........................................................................................................................3
8.1.2. COMPONENT INSPECTION ...................................................................................................................5
8.1.3. ECU CONNECTIONS............................................................................................................................12
8.1.4. WIRING DIAGRAM................................................................................................................................13
8-2
ELECTRICAL SYSTEM
BREVA 750
8-3
ELECTRICAL SYSTEM
BREVA 750
Key:
1. Dashboard
2. Coil
3. Fuel pump
4. Throttle potentiometer (TPS)
5. Injector
6. Bank angle sensor
7. Tail light
8. Battery
9. Secondary fuses
10. Main fuses
11. Engine control unit
12. Air temperature sensor
13. Speed sensor
14. Starter motor
15. Lambda Sensor
16. Engine oil pressure sensor
17. Engine speed sensor
18. Generator
19. Voltage regulator
20. Cylinder head temperature sensor
21. Front light
22. Dashboard air temperature sensor
8-4
ELECTRICAL SYSTEM
BREVA 750
8-5
ELECTRICAL SYSTEM
BREVA 750
1 DASHBOARD
DASHBOARD PINOUT
2 COIL
primary resistance: 0.5-0.6 Ω
secondary resistance: 3.3 KΩ
8-6
ELECTRICAL SYSTEM
BREVA 750
3 FUEL PUMP
Fuel pump:
power draw 4A (with power supply of 12V measured across
pins 1 and 2)
Fuel sensor:
resistance 1.4KΩ (measured across pins 3 and 4 with fuel
level 0 litres)
5 INJECTOR
resistance 16 Ω
8-7
ELECTRICAL SYSTEM
BREVA 750
7 TAIL LIGHT
rear parking light/brake light: 12V – 5/21 W
license plate light: 12V – 5 W
8 BATTERY
12 V – 14 Ah
9 SECONDARY FUSES
A – From ignition key to safety logic / starting (10 A).
B – From ignition key to lights, brake lights, horn, turn signals
(15 A).
C – From battery to injection permanent power supply (3 A).
D – From battery to injection (15 A).
E – Free
IMPORTANT Three spare fuses are supplied (3, 10, 15 A).
10 MAIN FUSES
F – From battery to voltage regulator (30 A).
G – From battery to ignition key and fuses C and D (30 A).
IMPORTANT One spare fuse is supplied.
8-8
ELECTRICAL SYSTEM
BREVA 750
13 SPEED SENSOR
hall effect sensor with 6 pulse/revolution square wave output
14 STARTER MOTOR
peak power draw approximately 100 A
8-9
ELECTRICAL SYSTEM
BREVA 750
15 LAMBDA SENSOR
oxygen sensor with heater
sensor output between 0 and 0.9 V (measured across pins 1
and 2)
heater resistance 12.8 Ω (measure across pins 3 and 4 at
68°F – 20°C)
18 GENERATOR
330 W
single phase generator
winding resistance 0.2-0.3 Ω
output voltage 20 V AC (measured with generator discon-
nected from electrical system and engine idling)
output voltage 65 V AC (measured with generator discon-
nected from electrical system and engine at 4000 rpm)
8 - 10
ELECTRICAL SYSTEM
BREVA 750
19 VOLTAGE REGULATOR
voltage to measure at battery poles (from 13.5 to 14V with
engine at 4000 rpm depending on load)
21 FRONT LIGHT
headlamp low beam / high beam (halogen): 12V - 55/60 W
H4
front parking light: 12V – 5W
8 - 11
ELECTRICAL SYSTEM
BREVA 750
8 - 12
ELECTRICAL SYSTEM
BREVA 750
8 - 13
ELECTRICAL SYSTEM
BREVA 750
8 - 14