MOTO GUZZI nevada Service Station Manual Download

Page: 110 / 198

Removing the engine from the vehicle

•

Remove the spark plug covers

•

Disconnect the caps from the spark

plugs

•

Remove the timing sensor fixing

screws.

•

Remove the sensor, being careful to

recover the gasket.

•

Disconnect the alternator connector

Engine from vehicle

NEVADA - NEVADA ANNIVERSARIO

ENG VE - 110

Summary of Contents for nevada

Page 1: ...SERVICE STATION MANUAL B043105 NEVADA NEVADA ANNIVERSARIO ...

Page 2: ... Guzzi original spare parts undergo quality control procedures to guarantee reliability and durability The descriptions and images in this publication are given for illustrative purposes only and are not binding While the basic characteristics as described and illustrated in this booklet remain unchanged Piaggio C S p A reserves the right at any time and without being required to update this publi...

Page 3: ...ntinually 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 wil...

Page 4: ...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 ...

Page 5: ...PICS 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 BODYWORK BODYW PRE DELIVERY PRE DE ...

Page 6: ...INDEX OF TOPICS CHARACTERISTICS CHAR ...

Page 7: ...ITH 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 syst...

Page 8: ...LY 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 rul...

Page 9: ...rfaces 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 har...

Page 10: ... SMELL WHEN FIRST USED THIS PHENOMENON SHOULD BE CONSIDERED NORMAL AND WILL DISAPPEAR AS SOON AS THE CLUTCH PLATES GET ADAPTED IT IS IMPORTANT TO STRAIN ENGINE COMPONENTS DURING RUN IN HOWEVER MAKE SURE 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 thr...

Page 11: ...k 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 Maximum length 2166 mm 85 27 in Maximum length Anniversario 2210 mm 87 01 in Maximum width 805 mm 31 69 in Maximum width Anniversario 800 mm 31 5 in Maximum height hand grips 1068 mm 42 04 in Maximum height Except rear view mirr...

Page 12: ...ive with gears ratio 16 21 1 1 3125 Gear ratios 1st gear 11 26 1 2 3636 Gear ratios 2nd gear 14 23 1 1 6429 Gear ratios 3rd gear 18 23 1 1 2778 Gear ratios 4th gear 18 19 1 1 0556 Gear ratios 5th gear 22 25 1 0 9 Final drive with cardan shaft ratio 8 33 1 4 825 Capacities CAPACITY Specification Desc Quantity Fuel reserve included 14 l 3 70 USgal Fuel reserve 4 l 1 056 US gal Engine oil Oil change ...

Page 13: ...il pressure LED Injection check warning light LED Frame and suspensions CHASSIS Specification Desc Quantity Type Modular double cradle high strength steel tubular chassis Steering rake 27 5 Trail 138 mm 5 43 in SUSPENSIONS Specification Desc Quantity Front hydraulic telescopic fork Ø 40 mm 1 57 in Travel 130 mm 5 12 in Rear V7 Special V7 Stone swinging arm in die cast light alloy 2 shock absorbers...

Page 14: ...nt inflation pressure 2 2 bar 220 kPa 31 90 PSI Front inflation pressure Anniversario 2 5 bar 250 kPa 36 3 PSI Front inflation pressure with passenger 2 5 bar 250 kPa 36 3 PSI Rear standard METZLER LASERTEC Rear size 130 90 V16 MC 67V Rear inflation pressure 2 2 bar 220 kPa 31 90 PSI Rear inflation pressure Anniversario 2 5 bar 250 kPa 33 6 PSI Rear inflation pressure with passenger 2 5 bar 250 kP...

Page 15: ...le to right fork leg M6x30 2 10 Nm 7 37 lbf ft Tighten using a 1 2 1 se quence 3 Screw fixing stanchions to upper and lower plate M10x40 4 50 Nm 36 88 lbf ft 4 Headstock ring nut M25x1 1 7 Nm 5 16 lbf ft The fork must fall to one side by itself 5 Headstock bushing M23x1 1 50 Nm 36 88 lbf ft NEVADA NEVADA ANNIVERSARIO Characteristics CHAR 15 ...

Page 16: ...7 lbf ft HANDLEBAR AND CONTROLS Pos Description Type Quantity Torque Notes 1 Switch fastener screw SWP 5 1 1 1 5 Nm 1 11 lb ft 2 Counterweight fixing screw M6 2 10 Nm 7 37 lb ft Loctite 243 3 Screw fastening the clutch control U bolt to the semi handlebar M6x25 2 10 Nm 7 37 lb ft Characteristics NEVADA NEVADA ANNIVERSARIO CHAR 16 ...

Page 17: ... fastening the brake pump U bolt to the semi handlebar M6x25 2 10 Nm 7 37 lb ft 2 Front brake calliper fixing screw M10x30 2 50 Nm 36 88 lb ft 3 Drilled screw for brake fluid pipe on pump and calliper 2 25 Nm 18 44 lb ft NEVADA NEVADA ANNIVERSARIO Characteristics CHAR 17 ...

Page 18: ...ew M6x16 2 10 Nm 7 37 lb ft 4 Headlamp support bracket fixing screw M10x40 2 50 Nm 36 88 lb ft CARROZZERIA PARTE ANTERIORE Pos Descrizione Tipo Quantità Coppia Note 1 Screw fastening stabiliser plate to fork M8x40 4 15 Nm 11 06 lbf ft Loctite 243 2 Screw fastening mudguard to stabiliser plate M6x11 4 10 Nm 7 37 lbf ft Loctite 243 Characteristics NEVADA NEVADA ANNIVERSARIO CHAR 18 ...

Page 19: ...scription Type Quantity Torque Notes 1 Front wheel axle M18x1 5 1 80 Nm 59 00 lbf ft 2 Front brake disc fixing screw M8x20 6 25 Nm 18 44 lbf ft Loctite 243 Central part NEVADA NEVADA ANNIVERSARIO Characteristics CHAR 19 ...

Page 20: ...Screw fixing exhaust silencer mount ing to frame M8x16 4 25 Nm 18 44 lbf ft Loctite 243 6 Battery supporting plate fixing screw M8x16 4 25 Nm 18 44 lbf ft FRAME CRADLES pos Description Type Quantity Torque Notes 1 Screw fixing stand beam to cradle M10x260 1 50 Nm 36 88 lbf ft 2 Screw fixing stand beam to cradle M8 1 1 25 Nm 18 44 lbf ft 3 Pin fixing engine gearbox to chassis M10x250 1 50 Nm 36 88 ...

Page 21: ...38 lb ft 2 Screw fastening rider footrest mounting to frame M8 2 2 25 Nm 18 44 lb ft Loct 243 SIDE STAND pos Description Type Quantity Torque Notes 1 Side stand retainer pin M10x1 2 5 1 10 Nm 7 38 lb ft 2 Lock nut for stand bolt M10x1 2 5 1 30 Nm 22 13 lb ft NEVADA NEVADA ANNIVERSARIO Characteristics CHAR 21 ...

Page 22: ...fixing screw M5x16 2 6 Nm 4 42 lb ft FUEL TANK pos Description Type Quantity Torque Notes 1 Rear tank fixing screw M8x45 1 25 Nm 18 44 lb ft 2 Screw fastening cap flange to tank M5x12 2 3 4 Nm 2 95 lb ft Characteristics NEVADA NEVADA ANNIVERSARIO CHAR 22 ...

Page 23: ...TIGHTENING TORQUE CENTRAL PART FILTER BOX pos Description Type Quantity Torque Notes 1 Air filter box cover fastening screw SWP 5x14 4 3 Nm 2 21 lb ft 2 Air filter box fastening screw to frame SWP 5x20 2 3 Nm 2 21 lb ft 3 Air filter box fastening screw SWP 5x20 9 3 Nm 2 21 lb ft NEVADA NEVADA ANNIVERSARIO Characteristics CHAR 23 ...

Page 24: ...ype Quantity Torque Notes 1 Side fairing fixing screw M5x9 2 4 Nm 2 95 lb ft LOCK KIT pos Description Type Quantity Torque Notes 1 Shear head screw fixing ignition lock M8x15 1 At the point of failure Characteristics NEVADA NEVADA ANNIVERSARIO CHAR 24 ...

Page 25: ...g clamp screw to the compensator M6 1 1 10 Nm 7 37 lb ft 3 Compensator fixing clamp screw to the silencer M6 2 10 Nm 7 37 lb ft 4 Lambda probe on compensator M18x1 5 1 38 Nm 28 03 lb ft 5 Nut fastening silencer to mounting plate M8 4 25 Nm 18 44 lb ft 6 Heat shield fixing screw M6x12 6 10 Nm 7 37 lb ft Loctite 270 7 Screw fixing silencer mounting plate to frame M8x40 2 25 Nm 18 44 lb ft NEVADA NEV...

Page 26: ...Pin fixing the rear calliper holding plate to swingarm M16x1 1 25 Nm 18 44 lbf ft 3 Nut fixing gearcase to swingarm M8 4 25 Nm 18 44 lbf ft Hold the stud bolt 4 Pin fixing swingarm to gearbox M20x1 2 Fully home with no preload 5 Lock nut on swingarm pin M20x1 2 50 Nm 36 88 lbf ft Hold the pin Characteristics NEVADA NEVADA ANNIVERSARIO CHAR 26 ...

Page 27: ...7 lbf ft Loctite 243 2 Lower pin fastening left shock absorber to swingarm M10x1 5 1 35 Nm 25 81 lbf ft 3 Stud bolt fixing right shock absorber to rear box M12x1 5 1 35 Nm 25 81 lbf ft 4 Screw fastening right shock absorber to stud bolt M6x16 1 10 Nm 7 37 lbf ft Loctite 243 NEVADA NEVADA ANNIVERSARIO Characteristics CHAR 27 ...

Page 28: ...ription Type Quantity Torque Notes 1 Pedal rubber fastening screw M6x12 4 10 Nm 7 38 lb ft 2 Screw fastening passenger footrest mounting to frame M8 2 2 25 Nm 18 44 lb ft Loct 243 Characteristics NEVADA NEVADA ANNIVERSARIO CHAR 28 ...

Page 29: ... 2 Rear brake disc fixing screw M8x25 6 25 Nm 18 44 lb ft Loctite 243 REAR BRAKE SYSTEM pos Description Type Quantity Torque Notes 1 Rear brake calliper fixing screw M8x30 2 25 Nm 18 44 lb ft 2 Drilled screw for brake pipe on cal liper 1 25 Nm 18 44 lb ft NEVADA NEVADA ANNIVERSARIO Characteristics CHAR 29 ...

Page 30: ...TS pos Description Type Quantity Torque Notes 1 Screw fastening taillight support to mudguard M5x14 3 4 Nm 2 95 lb ft 2 Rear turn indicator fixing screw M6 2 5 Nm 3 69 lb ft Characteristics NEVADA NEVADA ANNIVERSARIO CHAR 30 ...

Page 31: ... 1 Rear mudguard front and central fixing screw M6 2 1 10 Nm 7 37 lb ft 2 Rear mudguard side fixing screw M8x30 2 25 Nm 18 44 lb ft 3 Screw fixing license plate holder to mudguard reinforcement SWP M5x20 3 3 Nm 2 21 lb ft NEVADA NEVADA ANNIVERSARIO Characteristics CHAR 31 ...

Page 32: ...Type Quantity Torque Notes 1 Speed sensor fastening screw M6 1 10 Nm 7 37 lb ft 2 Fuse box bracket fixing screw M5x12 2 4 Nm 2 95 lb ft 3 Battery holder bracket fastening screw M6 2 Manual Characteristics NEVADA NEVADA ANNIVERSARIO CHAR 32 ...

Page 33: ... high specific power outputs JASO MA MA2 API SG AGIP GEAR MG SAE 85W 140 Transmission oil API GL 4 and GL 5 AGIP GEAR MG S SAE 85 W 90 Gearbox oil API GL 5 AGIP FORK 7 5W Fork oil SAE 5W SAE 20W AGIP GREASE SM 2 Gray black smooth textured lithium grease containing molybdenum disul phide Neutral grease or petroleum jelly Battery poles AGIP BRAKE 4 Brake fluid SAE J 1703 FMVSS 116 DOT 3 4 ISO 4925 C...

Page 34: ...INDEX OF TOPICS SPECIAL TOOLS S TOOLS ...

Page 35: ...Bevel gear set alignment pre fitting tool 19 92 60 00 Punch for gearcase sealing ring 19 90 70 00 Extractor for internal ring on drilled bolt 19 92 75 00 Extractor for external ring of gearcase bearing 19 92 62 00 Punch for bearing on bevel gear set pin ion NEVADA NEVADA ANNIVERSARIO Special tools S TOOLS 35 ...

Page 36: ...xternal ring of tapered bearing on bevel gear set pinion holding body 19 92 65 00 Punch for external ring of gearcase bear ing 19 92 76 00 Extractor for swinging arm holder bearing on gearbox cover Special tools NEVADA NEVADA ANNIVERSARIO S TOOLS 36 ...

Page 37: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 38: ...smission cables and controls I I I I I I I Steering bearings and steering clearance I I I I I I I Wheel bearings I I I I I I Brake discs I I I I I I I Air filter R R R R R R Engine oil filter R R R R R R R Lights operation aiming I I I I I I Vehicle general operation I I I I I I I Braking systems I I I I I I I Light circuit I I I I I I I Safety switches I I I I I I I Brake fluid 2 I I I I I I I Ge...

Page 39: ... EASY TO DRAIN NOTE RIDE SOME km miles TO WARM UP ENGINE OIL Place a container with 400 cm 25 cu in capacity under the drainage plug 3 Unscrew and remove the drainage plug 3 Unscrew and remove the breather cap 2 Drain the oil into the container allow several minutes for oil to drain out completely Check and if necessary replace the sealing washer of drainage plug 3 Remove any metal scrap attached ...

Page 40: ...he lubricant to drain back into the sump Keep the vehicle upright with both wheels on the ground Unscrew and remove the cap with dipstick Clean dipstick Refit the cap with dipstick into its hole without tightening Remove the cap with dipstick Check oil level by means of the oil dipstick The oil level is correct when it close to the MAX mark MAX maximum level MIN minimum level Add engine oil if req...

Page 41: ...he oil into the container allow several minutes for oil to drain out com pletely Check and if necessary replace the sealing washers of drainage plugs 1 Remove any metal scrap attached to the magnet of drainage plugs 1 Screw and tighten the drainage plugs 1 Drainage plugs tightening torque 1 12 Nm 1 2 kgm DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT DISPOSE OF ENGINE OIL IN A SEALED CONTAINER AND TAK...

Page 42: ...ealing ring 6 of the new engine oil filter Fit the new engine oil filter with the spring facing downwards Refit the cover 4 screw and tighten the screw 3 Air filter Remove the saddle Unhook the connector from the air box cover Remove the air box cover fixing screw Remove the air box cover Extract the air filter Maintenance NEVADA NEVADA ANNIVERSARIO MAIN 42 ...

Page 43: ...l Loosen the clamps that secure the sleeve to the intake manifolds Remove the sleeve Remove the battery Remove the MIU G3 control unit con nector support bracket fixing screw NEVADA NEVADA ANNIVERSARIO Maintenance MAIN 43 ...

Page 44: ...screw the clamp that secures the throttle body to the filter box Extract the throttle body laterally Remove the throttle body guard Loosen the gas cables fixing nuts on the throttle body and unhook them Maintenance NEVADA NEVADA ANNIVERSARIO MAIN 44 ...

Page 45: ...dy installation Connect the gas cables on the throttle body Correctly position the guides and tight en the nuts checking correct operation of the throttle grip Install the throttle body guard NEVADA NEVADA ANNIVERSARIO Maintenance MAIN 45 ...

Page 46: ...THAT THE CLAMP IS POSI TIONED CORRECTLY INCORRECT POSITIONING WILL CAUSE VEHICLE MALFUNCTIONS Connect the MIU G3 control unit con nector Install the MIU G3 control unit connec tor support bracket Install the sleeve taking care that they are inserted correctly Maintenance NEVADA NEVADA ANNIVERSARIO MAIN 46 ...

Page 47: ... Air filter housing FRAME pos Description Type Quantity Torque Notes 1 Screw fixing tank mounting rubber blocks to frame M8x14 2 25 Nm 18 44 lbf ft 2 Cradle front fixing screw M10x30 4 50 Nm 36 88 lbf ft NEVADA NEVADA ANNIVERSARIO Maintenance MAIN 47 ...

Page 48: ...m 18 44 lbf ft TIGHTENING TORQUE CENTRAL PART FILTER BOX pos Description Type Quantity Torque Notes 1 Air filter box cover fastening screw SWP 5x14 4 3 Nm 2 21 lb ft 2 Air filter box fastening screw to frame SWP 5x20 2 3 Nm 2 21 lb ft 3 Air filter box fastening screw SWP 5x20 9 3 Nm 2 21 lb ft Air filter housing removal Remove the saddle and the side fair ings Remove the battery Remove the rear wh...

Page 49: ...de body panels Splash guard Removing Specific operations for the vehicle Move the filter box to the side enough to allow removal of the fixing screws 3 on the right side of the filter box sup port Disconnect the neutral switch connec tor Lift the air filter box enough to allow the support plate to be removed sliding out neutral switch cabling NEVADA NEVADA ANNIVERSARIO Maintenance MAIN 49 ...

Page 50: ...at fastens the throttle body to the air filter box Disconnect the blow by and breather tubes Remove the air box cover Remove sliding the complete filter box out toward the rear Maintenance NEVADA NEVADA ANNIVERSARIO MAIN 50 ...

Page 51: ... body in the sleeve and tighten the clamp to secure it CAUTION TAKE PARTICULAR CARE THAT THE CLAMP IS POSI TIONED CORRECTLY INCORRECT POSITIONING WILL CAUSE VEHICLE MALFUNCTIONS Install the air box cover Connect the blow by and breather tubes NEVADA NEVADA ANNIVERSARIO Maintenance MAIN 51 ...

Page 52: ...ow tightening of the fixing screws 3 on the right side of the filter box support Move the filter box to the side enough to allow tightening of the fixing screws 2 on the left side of the filter box sup port Correctly position the air filter box on the support Fix the screws 1 of the fuse box sup port Maintenance NEVADA NEVADA ANNIVERSARIO MAIN 52 ...

Page 53: ...ning the brake pump U bolt to the semi handlebar M6 2 10 Nm 7 37 lbf ft Tighten using a 1 2 1 se quence 2 Front brake calliper fixing screw M10x30 2 50 Nm 36 88 lb ft 3 Drilled screw for brake fluid pipe on pump and calliper 2 25 Nm 18 44 lb ft NEVADA NEVADA ANNIVERSARIO Maintenance MAIN 53 ...

Page 54: ... minimum level MAX maximum level If the fluid does not reach at least the MIN reference mark Check brake pads and disc for wear If the pads and or the disc do not need replacing top up the fluid Top up Front brake Unscrew the two screws 1 of the brake fluid reservoir 2 using a Phillips screwdriver Lift and remove the cover 3 and screws 1 as well Remove the gasket 4 Rear brake Unscrew and remove th...

Page 55: ... FLUID WHEN USING A FUNNEL OR ANY OTHER ELEMENT MAKE SURE IT IS PERFECTLY CLEAN DO NOT EXCEED THE MAX LEVEL MARK WHEN TOP PING UP TOP UP TO MAX LEVEL MARK ONLY WHEN BRAKE PADS ARE NEW WHEN TOPPING UP DO NOT EXCEED THE MAX LEVEL MARK WHEN BRAKE PADS ARE WORN AS YOU RISK SPILLING FLUID WHEN CHANGING THE BRAKE PADS CHECK BRAKING EFFICIENCY IN CASE OF EXCESSIVE TRAVEL OF THE BRAKE LEVER OR POOR PERFOR...

Page 56: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 57: ... M6 1 10 Nm 7 37 lb ft 2 Fuse box bracket fixing screw M5x12 2 4 Nm 2 95 lb ft 3 Battery holder bracket fastening screw M6 2 Manual ELECTRICAL SYSTEM 02 pos Description Type Quantity Torque Notes 1 1 Coil fixing nut M6 2 2 10 Nm 7 37 lb ft NEVADA NEVADA ANNIVERSARIO Electrical system ELE SYS 57 ...

Page 58: ...pos Description Type Quantity Torque Notes 2 2 Timing sensor fastener screw 1 Nm lb ft Components arrangement key 1 Instrument panel 2 Coil Electrical system NEVADA NEVADA ANNIVERSARIO ELE SYS 58 ...

Page 59: ...he motorcycle and potential problems are defined on the following sections in order to reach the objectives of vehicle reliability Materials used and corresponding quantities The electrical system consists of the following cable harnesses and parts 1 Main Cable Harness 1 Ground cable Negative Engine 1 Left H V Cable 1 Left H V Cable Sheath Grey 1 Right H V Cable 1 Right H V Cable Sheath Black 3 Re...

Page 60: ...sertion of the relative rubber plug 2 Check the correct fastening of metallic bracket screw on the throttle body 3 Check the right and left injectors connection 4 Check the water temperature sensor connection Blue connector 5 Check correct insertion of H V Cables with Coils 6 Check whether the Grey H V Cable connects on the Coil with the Grey tape 7 Check whether the Grey H V Cable goes to the Lef...

Page 61: ... 23 Check the stand switch cable ties on the frame under the vehicle THE CIRCLED CONNECTORS ARE DEEMED MORE CRITICAL THAN THE OTHERS BECAUSE DISCONNECTION OF THESE MAY CAUSE THE VEHICLE TO STOP Undoubtedly the connection of the rest of connectors is also important and essential for the correct operation of the vehicle Front side TABLE A 1 Main cable harness 2 Clamp that secures the main cabling to...

Page 62: ...E B 1 Voltage regulator connector 2 Profile guards 3 Key connector 4 Left turn indicator connector 5 Flywheel connector If deemed necessary the voltage reg ulator connector 1 and the flywheel 2 can be tightened with a clamp in or der to avoid them disconnecting TABLE C 1 Key connector 2 Left turn indicator connector Both connectors once connected are positioned behind the steering tube Electrical ...

Page 63: ...hat secures the cables of the key and left turn indicator The gas cables must pass under the main cabling After placing the plastic protection check that all the cables come out from the specific slot NEVADA NEVADA ANNIVERSARIO Electrical system ELE SYS 63 ...

Page 64: ...ing in correspond ence to the grey tapings 6 Profile guards TABLE F Pass all the cabling as indicated and move all the connectors ensuring that they have been correctly connected behind the steering tube After placing the plastic protection check that all the cables come out from the specific slot TABLE G Electrical system NEVADA NEVADA ANNIVERSARIO ELE SYS 64 ...

Page 65: ...1 Front brake switch 2 Clamps 3 Cable guide TABLE G1 Add a cable guide TABLE H 1 Clamp 2 Cable guide NEVADA NEVADA ANNIVERSARIO Electrical system ELE SYS 65 ...

Page 66: ...or 3 Right injector 4 Rear stop switch 5 Gear in neutral switch 6 Left injector TABLE B 1 Rear stop switch 2 Clamps TABLE C 1 Side stand switch 2 Clamps TABLE D 1 Side stand cabling 2 Cable tie that secures the side switch cabling to the frame Electrical system NEVADA NEVADA ANNIVERSARIO ELE SYS 66 ...

Page 67: ...TABLE E 1 Side stand switch connector TABLE F 1 Starter motor actuator connector 2 Side stand cabling NEVADA NEVADA ANNIVERSARIO Electrical system ELE SYS 67 ...

Page 68: ...that the nut is secured correctly to the prescribed torque TABLE H 1 Gear in neutral switch 2 Cable grommet TABLE I 1 Main cable harness 2 Cable ties that secure the main cabling to the frame 3 Left cylinder coil 4 Right cylinder coil Electrical system NEVADA NEVADA ANNIVERSARIO ELE SYS 68 ...

Page 69: ...hrough the cable grommet 3 TABLE N 1 Left lambda probe connector 2 Cable tie that secures the cabling of the left lambda probe The left lambda probe goes behind to the saddle lock TABLE O 1 Neutral switch connector 2 Right Lambda probe connector 3 Cable tie that joins the switch connectors and the right lambda probe TABLE P 1 Battery positive NEVADA NEVADA ANNIVERSARIO Electrical system ELE SYS 69...

Page 70: ...he image and that there is perfect surface contact once the screw is tightened 3 Taillight connector 4 Speed sensor connector 5 Clamps TABLE P1 1 Cable guide that secures the rear stop light ca ble and the rear brake caliper pipe TABLE P2 1 Insert the cable tie to prevent the cables right and left turn indicators and license plate light from coming down in the hole 2 Big clamp 3 Taillight cable ha...

Page 71: ...TABLE Q 1 Taillight connector 2 Speed sensor connector Hide the taillight and speed sensor connectors between the filter box and mudguard NEVADA NEVADA ANNIVERSARIO Electrical system ELE SYS 71 ...

Page 72: ... S 1 Control unit connector 2 Control unit fastening bracket TABLE T 1 Module with resistance Pull UP TABLE U 1 Left cylinder coil The grey taping marks the left cylinder coil connector Electrical system NEVADA NEVADA ANNIVERSARIO ELE SYS 72 ...

Page 73: ...correct connection of the high voltage cable on the coils TABLE W 1 High voltage cable covered by black sheath for right cylinder 2 High voltage cable covered by grey sheath for left cylinder NEVADA NEVADA ANNIVERSARIO Electrical system ELE SYS 73 ...

Page 74: ...TABLE X 1 Pick Up connector TABLE Y 1 Left horn 2 Right horn Back side TABLE A 1 Rear speed sensor cabling 2 Medium clamps Electrical system NEVADA NEVADA ANNIVERSARIO ELE SYS 74 ...

Page 75: ...General wiring diagram key 1 Multiple connectors 2 Air temperature sensor 3 Speed sensor 4 Instrument panel NEVADA NEVADA ANNIVERSARIO Electrical system ELE SYS 75 ...

Page 76: ...Pull Up resistance 22 Fuses 23 Flywheel 24 Regulator 25 Lambda 1 left exhaust 26 Lambda 2 right exhaust 27 Side stand switch 28 Injection load relay 29 Fuel reserve sensor 30 Fuel pump 31 Injector 1 left cylinder 32 Injector 2 right cylinder 33 Coil 2 right cylinder 34 Coil 1 left cylinder 35 Neutral sensor 36 Oil sensor 37 Pick UP 38 Engine head temperature sensor 39 MIU G3 control unit 40 Diagno...

Page 77: ...hecks and inspections Dashboard Service warning light reset The system displays the function as follows the word MAInt is shown on the left LCD Display 1 after the mileage corresponding to the first servicing or any subsequent servicing is excee ded This is shown only after each start up for 5 seconds afterwards it will shift to the standard view NEVADA NEVADA ANNIVERSARIO Electrical system ELE SY...

Page 78: ...lightly lift the fuel tank being careful not to pull the pipes with the relative hooks Remove the connectors from the com partment behind the steering column Disconnect the three way connector 1 white NOTE THE ENGINE SIDE IS IDENTIFIED WITH THE LETTER A Measurement of resistance with engine off For a correct detection of the alternator resistance must be performed an am bient temperature measureme...

Page 79: ... 0 18 0 23 0 20 0 25 Empty voltage Disconnect the three way connector 1 For a correct detection of the alternator voltage a measurement must be carried out using alternatively the 3 engine side connector pins stage 1 pin 1 2 stage 2 pin 1 3 stage 3 pin 2 3 Take the measurements If there is a significant difference between one stage and another other than 15 V this means that the alternator is defe...

Page 80: ...RNING NEVER KEEP THE ENGINE RUNNING FOR MORE THAN ONE MINUTE FAILURE TO DO SO COULD CAUSE SERI OUS OVERHEATING DAMAGES TO THE MOTORCYCLE CIRCUITS COLD SHORT CIRCUIT CURRENT RPM 2000 4000 6000 8000 RMS DC current Arms average of the 3 stage currents 26 30 20 25 30 35 30 35 Voltage on battery poles with engine speed always between 3000 5000 RPM Start the engine after about one minute of operating br...

Page 81: ...er the fuel tank Pin out 1 control unit relay output blue yellow cable 2 ignition switch live control unit green red ca ble 3 starter motor violet cable 4 5 ignition switch live control unit green red ca ble ELECTRICAL ERRORS Starter command P0170 shorted to positive Error cause Shorted to positive excessive voltage at PIN 10 of the control unit connector Troubleshooting Shorted to positive This m...

Page 82: ... CHAPTER THE ENGINE DOES NOT START level indicators Petrol pump Input 4A to be measured between pins 1 and 2 with 12V supply voltage Fuel level sensor Resistance 1 4 Ohm to be measured between pins 3 and 4 with fuel level equal to 0 litres Lights list BULBS Specification Desc Quantity Low high beam light halogen 12 V 55 W 60 W H4 Front daylight running lights 12V 5W Turn indicator light 12 V 10 W ...

Page 83: ...ine kill starter relay instrument panel injection load relay 15 A D Battery positive Instrument panel turn indica tors 5 A E Battery positive MIU G3 Control unit 5A F Main fuse coil 1 and 2 injector 1 and 2 lambda 1 and 2 30 A Control unit Engine control unit Magneti Marelli MIU G3 NEVADA NEVADA ANNIVERSARIO Electrical system ELE SYS 83 ...

Page 84: ...electrical circuit diagram Speed sensor Location Sensor on the swingarm left side next to the rear brake calliper Connector under right fairing next to the Marelli control unit Pin out PIN PINS 1 3 Voltage approx 12 V PINS 2 3 Voltage between 0 6V 12V turning the rear wheel 1 Power supply voltage Orange White sen sor side 2 Output signal Blue Orange sensor side 3 Ground Blue sensor side ELECTRICAL...

Page 85: ...N 17 In the event that these checks have not detected the fault replace the sensor Engine rpm sensor Function It informs crankshaft position and speed to the Marelli control unit Operation Operating principle Inductive sensor sinusoidal type generated volt age two teeth are missing on the flywheel for the reference position Level in electrical circuit diagram engine speed sensor Location Sensor en...

Page 86: ...tor and the injection ECU connector If the values are incorrect restore them If the values are correct check the continuity of the two cables that go from PIN 20 to PIN 29 of the control unit connector If there is no continuity restore the cabling If there is continuity check interruption in the sensor and replace it Short circuit Conduct an electrical check of the sensor If the sensor check value...

Page 87: ...kΩ 5 Resistance at 20 C 3 747 kΩ 5 Resistance at 40 C 1 598 kΩ 5 Resistance at 60 C 0 746 kΩ 5 Resistance at 80 C 0 377 kΩ 5 Resistance at 100 C 0 204 kΩ 5 Pin out Grey cable harness side 0 5 V signal Blue green cable harness side Ground connection ELECTRICAL ERRORS Engine temperature sensor P0115 open circuit or shorted to positive shorted to negative Error cause Open circuit or shorted to positi...

Page 88: ...e cabling Shorted to negative Disconnect the sensor connector Check the sensor connector PIN 2 ground insulation If there is no ground insulation restore the cabling If PIN 2 is insulated from the ground and the error persists this means that there is a probable fault in the control unit Lambda sensor Function In charge of telling the control unit whether the mixture is lean or rich Operation Oper...

Page 89: ...IN 18 and 12 Troubleshooting Shorted to positive Disconnect the control unit connector and the sensor connector Verify that there is no short to battery positive on sensor connector PIN 1 corresponding to control unit connector PIN 18 if there is a short restore the cabling Verify that there is no short to battery positive on sensor connector PIN 2 corresponding to control unit connector PIN 12 if...

Page 90: ... Verify that there is no short to battery positive on sensor connector PIN 3 corresponding to control unit connector PIN 2 if there is a short restore the cabling The circuit is open Disconnect the control unit connector and the sensor connector Verify continuity of the cabling between the sensor connector and the control unit connector Control unit PIN 2 sensor PIN 3 Restore the cabling if necess...

Page 91: ...ive or carburetion excessively lean signal not plausible for abnormal title correction or probe signal fault Error cause Shorted to positive excessive voltage at PIN 11 or PIN 12 of the control unit connector Circuit open or shorted to negative interruption of the circuit or null voltage between control unit con nector PIN 11 and 12 Troubleshooting Shorted to positive Disconnect the control unit c...

Page 92: ...ambda probe heater P0141 shorted to positive shorted to negative open circuit Error cause Shorted to positive excessive voltage at PIN 35 of the control unit connector Shorted to negative lack of insulation from ground on the sensor connector PIN 4 The circuit is open interruption of the circuit Troubleshooting Shorted to positive Disconnect the control unit connector and the sensor connector Veri...

Page 93: ...in electrical circuit diagram Coils and in jectors Right injector position on the intake manifold connector on injector Electrical characteristics 14 8 Ohm 5 at 20 C 68 F Pin out 1 Power 12V red brown cable 2 Ground grey red cable ELECTRICAL ERRORS Front injector P0201 shorted to positive shorted to negative open circuit Error cause Shorted to positive excessive voltage at PIN 32 of the control un...

Page 94: ...onnectors Verify continuity of the cabling between the control unit connector and the injector connector control unit PIN 32 injector PIN 2 In the absence of continuity restore the cabling LEFT INJECTOR Level in electrical circuit diagram Coils and in jectors Left injector position on the intake manifold connector on injector Electrical characteristics 14 8 Ohm 5 at 20 C 68 F Pin out 1 Power 12V r...

Page 95: ...trol unit connectors Verify continuity of the cabling between the control unit connector and the injector connector control unit PIN 34 injector PIN 2 In the absence of continuity restore the cabling Fuel pump Function Fuel pump keeps pressure of the injectors supply duct Low fuel tells to the instrument panel about low fuel Operation Operating principle Low fuel it is a resistance that if correct...

Page 96: ...onnector PIN 1 and 2 toward the cabling If no voltage is read disconnect the control unit and verify insulation from battery positive of the relay PIN 1 or control unit PIN 22 Restore the cabling if necessary Shorted to negative Disconnect the injection relay No 28 on the electrical circuit diagram and the control unit Verify ground insulation of the relay connector PIN 1 and 2 toward the cabling ...

Page 97: ...e key to ON and activate the component through the diagnostics instrument Verify the presence of voltage on the coil connector PIN 1 if present restore the cabling otherwise replace the coil The circuit is open Carry out the check procedure of the coil and control unit connectors Verify continuity of the cabling between the coil and control unit Coil PIN 1 control unit PIN 1 In the absence of cont...

Page 98: ...it or shorted to negative Error cause Shorted to positive excessive voltage at PIN 8 of the control unit connector Circuit open or shorted to negative interruption of the circuit or null voltage at PIN 8 of the control unit connector Troubleshooting Shorted to positive Disconnect the coil connector turn the key to ON and activate the component through the diagnostics instrument Verify the presence...

Page 99: ...9 PSI in the engine Operation Operating principle normally closed switch With oil pressure above 0 35 0 2 bar 5 1 2 9 PSI open circuit Level in wiring diagram fuel reserve and oil pres sure Location sensor between the two heads at the back connector on the sensor Electrical characteristics With engine off closed circuit continu ity With engine started open circuit infin ite resistance Pin out Volt...

Page 100: ...ling switches Location sensor rear upper section of the gear box connector on the sensor Electrical characteristics Gear in neutral closed circuit 0 V on wire from control unit to sensor switch in continuity Gearshift engaged circuit open 12 V on the wire from control unit to sensor Pin out 1 Voltage 12V green black cable Instrument panel NEUTRAL warning light always off Troubleshooting Carry out ...

Page 101: ...trol unit PIN 17 to instrument panel PIN 10 and verify continuity If there is no continuity restore the cabling If there is no continuity replace the cabling Clutch lever sensor Function It tells the clutch lever position to the control unit Operation Operating principle In order to start the engine pull the clutch also with the gear in neutral Level in electrical circuit diagram Start up ena blin...

Page 102: ... clutch released there is continuity between the two PINs If there is continuity replace the sensor If there is no continuity this means that the blue violet cable which goes from the sensor PIN 2 to the control unit PIN 15 is shorted to ground Side stand sensor Function It tells the side stand position to the control unit Operation Operating principle If the gear is engaged and the side stand is ...

Page 103: ... operated and gear engaged starts but with the side stand extended disconnect the sensor connector and check that with side stand extended there is not continuity between the 2 PINS If present replace the sensor If absent disconnect from control unit PIN 19 and check insulation from the ground of the grey yellow cable between sensor and control unit Air temperature sensor instrument panel Function...

Page 104: ...e the cabling If there is continuity check correct resistance of the sensor If the sensor resistance is not OK replace the sensor If OK check with the key turned ON for the presence of voltage at sensor connector PIN 1 If there is no voltage at PIN 1 replace the instrument panel If about 12 V is present restore the cabling there is a short to battery If about 5 V is present connect a 10 kOhm resis...

Page 105: ...ircuit diagram start up ena bling switches Location sensor right light switch connector next to the headstock right side Electrical characteristics STOP position the circuit is open RUN position closed circuit continui ty PIN pink yellow cable looking at the cabling voltage 0 V with engine kill in STOP 12V if engine kill in RUN Blue Green cable cable harness side always voltage 12 V with key on DI...

Page 106: ...tors ECU PIN 1 Throttle position sensor supply Power out put 2 Lambda probe signal ground Analogue input 3 Rpm indicator control Frequency output 4 Cylinder head temperature sensor signal Analogue input 5 6 Right injector control Power output 7 Engine revolution sensor Frequency input 8 Lambda probe signal positive Analogue input 9 Diagnosis line K Communication line 10 Diagnosis line L Communicat...

Page 107: ...gh beam lights input 4 n c 5 n c 6 Rear left arrow output 7 Front left arrow output 8 EFI input 9 Left arrow input 10 Neutral input 11 Oil input 12 Air temperature input 13 Speed sensor power supply 14 Ground connection 15 K Line 16 n c 17 Speed input 18 Engine revs input 19 n c 20 Reserve input 21 Key 22 Ground connection 23 Battery 24 Front right arrow output 25 Rear right arrow output 26 Batter...

Page 108: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 109: ...x16 4 25 Nm 18 44 lbf ft Loctite 243 6 Battery supporting plate fixing screw M8x16 4 25 Nm 18 44 lbf ft Vehicle preparation To arrange for the removal of the engine block you must first remove the saddle fuel tank side fairings and the battery From the front secure the vehicle with belts attached to a hoist Position a centre stand under the engine sump Position an engine support so as not to damag...

Page 110: ...e spark plug covers Disconnect the caps from the spark plugs Remove the timing sensor fixing screws Remove the sensor being careful to recover the gasket Disconnect the alternator connector Engine from vehicle NEVADA NEVADA ANNIVERSARIO ENG VE 110 ...

Page 111: ...injec tors and disconnect them Disconnect the engine temperature sensor connector Loosen the clamps securing the sleeve and remove it Disconnect the oil pressure bulb con nector NEVADA NEVADA ANNIVERSARIO Engine from vehicle ENG VE 111 ...

Page 112: ...gine ground wires Disconnect the clutch cable from the lever Disconnect the clutch cable from the disengagement lever Remove the screws which fix the air fil ter box to the frame Engine from vehicle NEVADA NEVADA ANNIVERSARIO ENG VE 112 ...

Page 113: ... sensor connec tor Lift the filter box and slide the cabling out through the support plate After removing the clamp disconnect the speed sensor and rear stop Disconnect the side stand switch con nector NEVADA NEVADA ANNIVERSARIO Engine from vehicle ENG VE 113 ...

Page 114: ...crews fixing the cradle making sure to recover the nuts and washers Remove the central pin by pulling it from the right side of the motorcycle Remove the fixing pin of the rear left shock absorber Engine from vehicle NEVADA NEVADA ANNIVERSARIO ENG VE 114 ...

Page 115: ...ll it from the pin on the drive shaft Remove the side pins taking care to recover the nuts Lift the frame and separate it from the engine block Installing the engine to the vehicle Place the frame on the engine block NEVADA NEVADA ANNIVERSARIO Engine from vehicle ENG VE 115 ...

Page 116: ...etainer nuts Insert the screws with the relative re tainer nuts and washers of the cradles to the frame Tighten the fixing screws of the cradle to the prescribed torque the central pin and the side pins of the engine to the frame Install the protections of the fixing screws of the cradles Engine from vehicle NEVADA NEVADA ANNIVERSARIO ENG VE 116 ...

Page 117: ...orber via the appropriate pin with corresponding nut Connect the side stand switch connec tor Lift the filter box and thread the cable through the backing plate Connect the neutral sensor connector Connect the speed sensor and rear stop NEVADA NEVADA ANNIVERSARIO Engine from vehicle ENG VE 117 ...

Page 118: ... cable to the trip lev er Connect the clutch cable to the lever Install the sleeve paying attention to the correct positioning of the clamps before tightening them Engine from vehicle NEVADA NEVADA ANNIVERSARIO ENG VE 118 ...

Page 119: ...ect the oil pressure bulb connec tor Attach the engine ground leads Connect the engine temperature sen sor connector Connect and secure the injectors NEVADA NEVADA ANNIVERSARIO Engine from vehicle ENG VE 119 ...

Page 120: ... Install the timing sensor with its seal Connect the alternator connector Connect the spark plug tubes Install the covers of the spark plugs Engine from vehicle NEVADA NEVADA ANNIVERSARIO ENG VE 120 ...

Page 121: ...INDEX OF TOPICS ENGINE ENG ...

Page 122: ...TO CONSULT THE CHAPTER ABOUT THE ENGINE AND ITS COMPONENTS PLEASE REFER TO THE APPROPRIATE MANUAL MSS Engine V750 IE My2012 Engine NEVADA NEVADA ANNIVERSARIO ENG 122 ...

Page 123: ...INDEX OF TOPICS POWER SUPPLY P SUPP ...

Page 124: ...Circuit diagram key 1 Fuel tank 2 Throttle body 3 Fuel filter 4 Fuel delivery pipe 5 Fuel pump unit Injection Power supply NEVADA NEVADA ANNIVERSARIO P SUPP 124 ...

Page 125: ...witch 3 Battery 4 Fuel pump 5 Coils 6 Instrument panel 7 Air temperature sensor 8 Throttle valve position sensor 9 Injectors 10 Crankshaft position sensor 11 Engine temperature sensor 12 Lambda probe NEVADA NEVADA ANNIVERSARIO Power supply P SUPP 125 ...

Page 126: ...l sensors engine revs engine temperature etc or values set by the control unit injection time ignition advance etc ENGINE PARAMETER READING SCREEN PAGE Navigator characteristic P A D S characteristic Description Value Engine rpm Engine rpm Rpm the minimum value is set by the control unit cannot be adjusted Entire throttle position Throttle angle Rpm the minimum value is set by the control unit can...

Page 127: ...e Injection time Left cylinder adaptive correc tion Lambda adaptive gain 1 Right cylinder adaptive correc tion Lambda adaptive gain 2 Atmospheric pressure Atmospheric pressure The value is estimated by the control unit Intake pressure Intake pressure Pressure detected in the intake duct Target idle rpm Idling target is a target value for the engine speed at the minimum set by the control unit with...

Page 128: ...acteristic P A D S characteristic Navigator Description Value P A D S Description Value Lean title left cylinder Lean title cylinder 1 Yes No Yes No Lean title right cylinder Lean title cylinder 2 Yes No Yes No Idle motor Idle motor Ready for start Open loop Closed loop OK start up O Loop ClosLoop Closed Left cylinder lambda control Lambda circuit 1 Open loop Closed loop Open Closed Diagnosis Erro...

Page 129: ... No Not detectable Yes No Fan relay Fan relay Not activated Activated OFF 2 active 1 active req 1 req 2 Engine mode Engine mode Undetermined Start up Start up stabilized Start up with decelera tion Start up with acceleration Idling compensated for start up En gine stable outside idling Engine idling Undeterm Start Stabil Start_dec Start_acc Min_Comp Stable Min Accel Decel Cut Off RCUT OFF Engine m...

Page 130: ... circuit to ground P0 13 0 Control of air fuel ratio Left lamb da probe Lambda probe signal Bank 1 short circuit to positive open circuit short circuit to negative or excessively lean carburation signal not plausible for title correction Short circuit to positive Open or short circuit to ground Signal not plausible P0 13 5 Left lambda probe heater Lambda heater circ Bank 1 short circuit to positiv...

Page 131: ...t short circuit to positive short circuit or open circuit to negative Short circuit to positive Short circuit or open circuit to ground P0 50 5 Idle control Idle control Stepper motor short circuit to positive short circuit to negative open circuit overpressure Short circuit to positive Short circuit to ground Open circuit Overpressure above specifications P0 53 0 Light relay Headlamp relay comman...

Page 132: ... Throttle position self acquisi tion TPS reset Saved data file download Mem data download Down load Clearing Clearing memorized data Mem data download Down load Clearing Self adjustable parameters re set Self adjustable parameters re set Power supply NEVADA NEVADA ANNIVERSARIO P SUPP 132 ...

Page 133: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 134: ... fixing screw M8x20 6 25 Nm 18 44 lbf ft Loctite 243 Removing the front wheel Place the vehicle on a stable support so that the front wheel does not touch the ground Remove the brake calliper without dis connecting the oil pipes Remove the front wheel Handlebar V7 SPECIAL V7 STONE Suspensions NEVADA NEVADA ANNIVERSARIO SUSP 134 ...

Page 135: ... 2 Counterweight fixing screw M6 2 10 Nm 7 37 lb ft Loctite 243 3 Screw fastening the clutch control U bolt to the semi handlebar M6x25 2 10 Nm 7 37 lb ft Front fork FRONT SUSPENSION STEERING pos Description Type Quantity Torque Notes 1 Stanchion cap 2 50 Nm 36 88 lbf ft NEVADA NEVADA ANNIVERSARIO Suspensions SUSP 135 ...

Page 136: ... 50 Nm 36 88 lbf ft 4 Headstock ring nut M25x1 1 7 Nm 5 16 lbf ft The fork must fall to one side by itself 5 Headstock bushing M23x1 1 50 Nm 36 88 lbf ft Diagram Key 1 Screw 2 Washer 3 Screw 4 Complete left sleeve 5 Upper bushing 6 Washer 7 Sealing ring 8 Snap ring 9 Dust guard 10 Stem 11 Lower bushing 12 Buffer 13 Counter spring 14 Complete pumping member Suspensions NEVADA NEVADA ANNIVERSARIO SU...

Page 137: ...oving the fork legs NOTE PAY ATTENTION TO THE TYPE OF FORK FITTED DURING REMOVAL AND FITTING TWO DIFFERENT SUPPLIES CAN BE FOUND ON THIS MOTORCYLCE MARZOCCHI OR KAIFA TO DISTINGUISH BETWEEN THEM IT IS NECES SARY TO PROCEED WITH THE REMOVAL THE MARZOC CHI FORK UNLIKE THE KAIFA ONE IS EQUIPPED WITH A WASHER ABOVE THE PRELOAD TUBE AND A SHIM HOUSED BELOW The vehicle is equipped with a non adjustable ...

Page 138: ...D ON A VICE MAKE SURE NOT TO DAMAGE THEM BY OVERTIGHTENING ALWAYS USE ALUMINIUM JAW CAPS Remove the front wheel Remove the front mudguard Remove the key switch cover Undo and remove the two screws and collect the washers Move the instrument panel forwards Suspensions NEVADA NEVADA ANNIVERSARIO SUSP 138 ...

Page 139: ...ning it slightly first in one direction then to the opposite direction Draining oil To drain out the oil follow these steps Remove the stanchion Tighten the removed stanchion in a vice fitted with aluminium jaw caps in order to avoid damaging them NEVADA NEVADA ANNIVERSARIO Suspensions SUSP 139 ...

Page 140: ...g during extraction Press the bearing tube inside the wheel holder fork leg Remove the preload tube and the spring MARZOCCHI FORK PROCEDURE Be careful not to damage the O Ring during extraction Remove the washer Press the bearing tube inside the wheel holder fork leg Remove the preload tube and the spring Remove the shim Suspensions NEVADA NEVADA ANNIVERSARIO SUSP 140 ...

Page 141: ...ged elements If there are no damaged or worn ele ments refit the stanchion otherwise replace the damaged elements NOTE FOR EASY DRAINAGE OF THE OIL INSIDE THE PISTON ROD PRESS THE STANCHION IN THE WHEEL HOLDER SLEEVE TO PUMP OIL OUT Disassembling the fork Drain all the oil from the stem Block the wheel holder fork leg on the vice Undo the bottom screw and remove it with the corresponding gasket NE...

Page 142: ...AREFUL NOT TO DAMAGE THE FORK LEG RIM Slide off the bearing tube from the wheel holder fork leg together with the sealing ring the cap the upper bush ing and lower bushings NOTE WHEN REMOVING THE PIPE FROM THE WHEEL HOLDER FORK LEG SOME PARTS MAY REMAIN INSIDE THE FORK LEG IF THIS OCCURS THESE PARTS MUST BE RE MOVED AFTERWARDS BEING CAREFUL NOT TO DAM AGE THE FORK LEG RIM AND THE UPPER BUSHING SEA...

Page 143: ...n Slide off the pumping member unit from the holding tube if it is damaged replace the counter spring and the ring Reassembling the fork CAUTION ALL COMPONENTS MUST BE CAREFULLY WASHED AND DRIED WITH COMPRESSED AIR BE FORE REFITTING Carry out any necessary service oper ation Insert the pumping member unit with the counter spring and the ring in the bearing tube Check that the upper guide bushing i...

Page 144: ...e bearing tube Reassemble the bearing tube in the wheel holder fork leg Insert the bearing tube in the wheel holder and push it until it stops Screw the bottom screw and tighten it to the prescribed torque Suspensions NEVADA NEVADA ANNIVERSARIO SUSP 144 ...

Page 145: ...r Pour oil into the bearing tube so that it also fills the internal grooves of the pumping member rod Pump with the bearing tube making sure the oil has completely filled the pumping member rod Introduce the spring and the preload tube Place the cap on the bearing tube tak ing care not to damage the O ring Then tighten the cap to the prescribed torque NEVADA NEVADA ANNIVERSARIO Suspensions SUSP 14...

Page 146: ...he oil level and the rim THE SLEEVE MUST BE PERFECTLY UPRIGHT IN ORDER TO MEASURE THE CORRECT OIL LEVEL THE OIL LEVEL MUST BE THE SAME IN BOTH STANCHIONS Characteristic Marzocchi Oil level from the sleeve edge with out the spring and with stanchion to end of stroke 150 mm 5 9 in Kaifa Oil level from the sleeve edge without the spring and with stanchion to end of stroke 120 1 5 mm 4 72 0 06 in Intr...

Page 147: ...mage the O ring Then tighten the cap to the prescribed torque Installing the fork legs Insert the stem on the vehicle going through the lower plate and the upper plate Tighten the screws to the prescribed torque NEVADA NEVADA ANNIVERSARIO Suspensions SUSP 147 ...

Page 148: ...l axle to right fork leg M6x30 2 10 Nm 7 37 lbf ft Tighten using a 1 2 1 se quence 3 Screw fixing stanchions to upper and lower plate M10x40 4 50 Nm 36 88 lbf ft 4 Headstock ring nut M25x1 1 7 Nm 5 16 lbf ft The fork must fall to one side by itself 5 Headstock bushing M23x1 1 50 Nm 36 88 lbf ft Suspensions NEVADA NEVADA ANNIVERSARIO SUSP 148 ...

Page 149: ...he handlebar Move the handlebar forward be care ful not to turn over the front brake fluid reservoir Remove the instrument panel Working from both sides undo and re move the screw locking the upper plate to the front fork Unscrew and remove the central nut NEVADA NEVADA ANNIVERSARIO Suspensions SUSP 149 ...

Page 150: ...t the ring nut Fit the upper plate on the front fork Tighten the central nut Working from both sides tighten the screw locking the upper plate to the front fork Fit the handlebar Fit the instrument panel Suspensions NEVADA NEVADA ANNIVERSARIO SUSP 150 ...

Page 151: ... Loctite 243 2 Lower pin fastening left shock absorber to swingarm M10x1 5 1 35 Nm 25 81 lbf ft 3 Stud bolt fixing right shock absorber to rear box M12x1 5 1 35 Nm 25 81 lbf ft 4 Screw fastening right shock absorber to stud bolt M6x16 1 10 Nm 7 37 lbf ft Loctite 243 Removing Undo and remove the upper screw NEVADA NEVADA ANNIVERSARIO Suspensions SUSP 151 ...

Page 152: ... Undo and remove the lower screw Suspensions NEVADA NEVADA ANNIVERSARIO SUSP 152 ...

Page 153: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 154: ...ft 2 Pin fixing the rear calliper holding plate to swingarm M16x1 1 25 Nm 18 44 lbf ft 3 Nut fixing gearcase to swingarm M8 4 25 Nm 18 44 lbf ft Hold the stud bolt 4 Pin fixing swingarm to gearbox M20x1 2 Fully home with no preload 5 Lock nut on swingarm pin M20x1 2 50 Nm 36 88 lbf ft Hold the pin Chassis NEVADA NEVADA ANNIVERSARIO CHAS 154 ...

Page 155: ...n Type Quantity Torque Notes 1 Rear wheel axle nut M16x1 5 1 120 Nm 88 51 lb ft 2 Rear brake disc fixing screw M8x25 6 25 Nm 18 44 lb ft Loctite 243 Removing Remove the left silencer NEVADA NEVADA ANNIVERSARIO Chassis CHAS 155 ...

Page 156: ...ng the brake pipe from the retainers on the swingarm Unscrew and remove the fixing screw of the calliper holder Remove both rear suspensions Unscrew and remove the nut and col lect the washer Chassis NEVADA NEVADA ANNIVERSARIO CHAS 156 ...

Page 157: ... Loosen the wheel pin locking screw Remove the wheel pin and collect the spacer Remove the rear wheel Unscrew the seal clamp Lift the bellows NEVADA NEVADA ANNIVERSARIO Chassis CHAS 157 ...

Page 158: ...joint Check that the rubber bellows are not cut or pierced otherwise replace it Check that the swingarm pin threads and the swingarm fixing nuts are not damaged de formed or flattened otherwise replace them Check that the sleeve grooves are not damaged deformed or deteriorated otherwise re place the sleeve Check that the spring is not deformed otherwise replace it Check that the sealing ring Seege...

Page 159: ...on the right side rests on the bearing fitted on the gearbox cover Tighten thoroughly the pin on the right side without locking it Operate the swingarm and make sure it oscillates freely without clearance Screw in the lock nuts on the pins lock ing them thoroughly Screw the clamp NEVADA NEVADA ANNIVERSARIO Chassis CHAS 159 ...

Page 160: ... Undo the four nuts and collect the washers Slide off the gearcase together with the swingarm Slide off the sleeve from the pinion Slide off the spring Slide off the sealing ring Slide off the base Chassis NEVADA NEVADA ANNIVERSARIO CHAS 160 ...

Page 161: ...e the housing of the swingarm Slide the complete case of the gear case Lock on the vice the sealing tool 19907100 of the bevel gear pair Insert the grooved shank of the pinion on the tool and unscrew the nut NEVADA NEVADA ANNIVERSARIO Chassis CHAS 161 ...

Page 162: ...n Slide off the shim adjustment washer Slide off the O ring Slide off the oil seal Slide of the tapered bearing from the case Slide off the O ring Slide off the spacer Slide off the two shim washers Chassis NEVADA NEVADA ANNIVERSARIO CHAS 162 ...

Page 163: ...e not damaged or worn otherwise replace them Check that the adjustment washers are not deformed or broken otherwise replace them Check that the sealing rings are not shattered spoiled or worn otherwise replace them Montaggio If the bevel pinion should be replaced replace also the crown fitted on the housing The pinion and the crown should have the same number stam ped NEVADA NEVADA ANNIVERSARIO Ch...

Page 164: ...ase using the suitable punch 19926400 Fit the adjustment shim washer Fit the internal ring of the bearing on the pinion using the suitable punch 19926200 Fit both shim washers on the pinion Fit the spacer on the pinion Fit the O ring Chassis NEVADA NEVADA ANNIVERSARIO CHAS 164 ...

Page 165: ...ase us ing the suitable punch 19926100 Fit the oil seal Fit the O ring Fit the spacer Insert the grooved shank of the pinion on the tool 19907100 and tighten the nut Smontaggio gruppo scatola NEVADA NEVADA ANNIVERSARIO Chassis CHAS 165 ...

Page 166: ...washers Slide off the complete cover Slide off the gaskets Slide off the shimming ring Remove the O ring from the groove on the drilled bolt From the cover slide off The needle bearing Remove the internal ring of the needle bearing using a suitable punch 19907000 Remove the washer Remove the washer Chassis NEVADA NEVADA ANNIVERSARIO CHAS 166 ...

Page 167: ... Undo the screws and collect the corre sponding safety plates Remove the conical crown Slide off the drilled bolt from the bear ing Remove the sealing ring NEVADA NEVADA ANNIVERSARIO Chassis CHAS 167 ...

Page 168: ... on the cover the external ring of the bearing on the housing the groove for the circlip on the drilled bolt are not worn deformed or spoiled otherwise replace them Check that the sealing ring on the housing is not shattered or is still flexible otherwise replace it That the needle bearing on the housing does not have flattened or worn rollers otherwise replace it Check efficiency of every compone...

Page 169: ... bearing cage in the housing Check alignment between pinion teeth and the crown teeth If alignment is not regular properly vary the thickness of the ring between the pinion and the tapered bearing Also check the contact area between the pinion teeth and the crown teeth proceeding as follows Apply suitable colours available in the market on the pinion teeth NEVADA NEVADA ANNIVERSARIO Chassis CHAS 1...

Page 170: ... brake disc side Turn the pinion in the riding direction with the crown braked so that the rota tion is carried out under load and leaves a contact mark on the pinion surface If the contact is regular the mark on the pinion teeth will be like this the pinion is seen from the crankshaft side If the contact is like this the crown is too near the pinion rotation axis de tach the crown by increasing s...

Page 171: ... like this the pinion is too far from the rotation axis of the crown approach the pinion by increas ing spacer thickness If the contact is like this the crown is too far from the pinion rotation axis ap proach the crown by reducing spacer thickness Montaggio gruppo scatola Fit the washer on the gearcase NEVADA NEVADA ANNIVERSARIO Chassis CHAS 171 ...

Page 172: ...using us ing the suitable punch 19926000 Fit the external ring of the needle bear ing on the housing using the suitable punch 19926500 Fit the bearing on the cover using the suitable punch Chassis NEVADA NEVADA ANNIVERSARIO CHAS 172 ...

Page 173: ... bear ing on the drilled bolt using the suitable punch 19927900 Insert the sealing ring in the drilled bolt Fit the drilled bolt on the cover Fit the crown Fit the plates and tighten the screws NEVADA NEVADA ANNIVERSARIO Chassis CHAS 173 ...

Page 174: ... ring Insert the gaskets and the shimming ring on the cover Tighten the screws with plates and washers Fit the braking disc on the drilled bolt by locking the screws with the washers using a torque wrench Chassis NEVADA NEVADA ANNIVERSARIO CHAS 174 ...

Page 175: ...d that the oil passage grooves with holes should be fitted vertically observing the grooves one should be facing up wards and the other facing the ground Installing Insert the sleeve and base on the bevel pinion of the gearcase NEVADA NEVADA ANNIVERSARIO Chassis CHAS 175 ...

Page 176: ... the holes of the swingarm Screw the nuts with the washers with out locking them Exhaust EXHAUST SYSTEM Pos Description Type Quantity Torque Notes 1 Exhaust pipe fixing nut to the engine M6 4 10 Nm 7 37 lb ft Chassis NEVADA NEVADA ANNIVERSARIO CHAS 176 ...

Page 177: ...t fastening silencer to mounting plate M8 4 25 Nm 18 44 lb ft 6 Heat shield fixing screw M6x12 6 10 Nm 7 37 lb ft Loctite 270 7 Screw fixing silencer mounting plate to frame M8x40 2 25 Nm 18 44 lb ft key 1 Right exhaust pipe 2 Left exhaust pipe 3 Exhaust manifold fitting 4 Left silencer clamp 5 Gasket 6 Spacer 7 Ring nut 8 Washer 9 Nut 10 Left silencer 11 Right silencer 12 Clamp 13 Right plate 14 ...

Page 178: ...tem components get very hot and remain in this condition for a certain time interval after the engine has been switched off Before handling these components make sure that you are wearing insulating gloves or wait until the engine and the exhaust system have cooled down Loosens the clamps between the ex haust pipes and catalytic converter Unscrew and remove the muffler fixing nut and collect the s...

Page 179: ...the exhaust ring fixing nuts taking care to recover the washers Remove the spacers Remove the ring nuts Remove the starter motor in order to be able to disconnect the left lambda probe connector NEVADA NEVADA ANNIVERSARIO Chassis CHAS 179 ...

Page 180: ...e cable grommet Loosen the clamps between the joint and the exhaust manifolds Remove the manifolds Removing the lambda sensor Disconnect the left lambda probe 1 and right lambda probe 2 connector Unscrew and remove the lambda probes Chassis NEVADA NEVADA ANNIVERSARIO CHAS 180 ...

Page 181: ...INDEX OF TOPICS BODYWORK BODYW ...

Page 182: ... M8x40 4 15 Nm 11 06 lbf ft Loctite 243 2 Screw fastening mudguard to stabiliser plate M6x11 4 10 Nm 7 37 lbf ft Loctite 243 3 Top fairing fixing screw M6 2 10 Nm 7 37 lbf ft Driving mirrors Loosen the lock nut 2 Undo and remove the mirror by oper ating the nut 1 Bodywork NEVADA NEVADA ANNIVERSARIO BODYW 182 ...

Page 183: ...e headlight assembly Working from both sides disconnect the two connectors Remove the horn by undoing the screw Disassembling the lock Remove the left side fairing Remove the ignition switch assembly by loosening the two screws 1 See also Side body panels NEVADA NEVADA ANNIVERSARIO Bodywork BODYW 183 ...

Page 184: ...ight assem bly connector Undo and remove the three fixing screws Remove the rear headlight See also Rear mudguard Passenger footrest plate Unscrew and remove the screw 1 Unscrew and remove the two screws 2 remove the footrest holder Bodywork NEVADA NEVADA ANNIVERSARIO BODYW 184 ...

Page 185: ...Side body panels Remove the saddle Working on both sides remove the up per screw Remove the side fairing Rear mudguard ANNIVERSARIO NEVADA NEVADA ANNIVERSARIO Bodywork BODYW 185 ...

Page 186: ... 7 37 lb ft 2 Rear mudguard side fixing screw M8x30 2 25 Nm 18 44 lb ft 3 Screw fixing license plate holder to mudguard reinforcement SWP M5x20 3 3 Nm 2 21 lb ft NEVADA ANNIVERSARIO Remove the saddle Remove the upper central screw 1 that secures the mudguard to the frame Bodywork NEVADA NEVADA ANNIVERSARIO BODYW 186 ...

Page 187: ... Remove the lateral screws 3 that se cure the mudguard and the passenger handgrips from both sides taking care to recover the nuts Disconnect the taillight connector Remove the rear mudguard by sliding the light cabling through the wheel housing NEVADA NEVADA NEVADA ANNIVERSARIO Bodywork BODYW 187 ...

Page 188: ...laced on the internal side of the mud guard Undo the fixing screw of the rear shock absorber Remove the side bar Unscrew and remove the two fixing screws of the handgrip Remove the handgrip Bodywork NEVADA NEVADA ANNIVERSARIO BODYW 188 ...

Page 189: ...front fixing screws of the rear mudguard Undo and remove the two fixing screws placed under the rear mudguard Disconnect the taillight connector Remove the rear mudguard NEVADA NEVADA ANNIVERSARIO Bodywork BODYW 189 ...

Page 190: ...plate light connectors Undo and remove the two fixing screws of the wheel housing Remove the wheel housing Splash guard Remove the lower screws 1 Remove the upper screws 2 taking care to recover the nuts Bodywork NEVADA NEVADA ANNIVERSARIO BODYW 190 ...

Page 191: ...rew Partially lift the fuel tank in order to be able to disconnect the fuel hose fitting avoiding damaging it CAUTION PAY PARTICULAR ATTENTION DURING THE LIFTING OP ERATION IN THAT THE FUEL HOSE FITTING CAN BE DAM AGED Disconnect the connector NEVADA NEVADA ANNIVERSARIO Bodywork BODYW 191 ...

Page 192: ... Disconnect the fuel pipe Remove the fuel breather pipe Remove the fuel tank by sliding it off and back Bodywork NEVADA NEVADA ANNIVERSARIO BODYW 192 ...

Page 193: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 194: ...screws Electrical system Main switch Headlamps high beam lights low beam lights tail lights front and rear and their warning lights Headlight adjustment according to regulations in force Front and rear stop light switches and their bulbs Turn indicators and their warning lights Instrument panel lights Instrument panel fuel and temperature indicator if present Instrument panel warning lights Horn E...

Page 195: ...ES INTO CONTACT WITH YOUR EYES OR SKIN WASH WITH ABUN DANT WATER FOR APPROX 15 MIN AND SEEK IMMEDIATE MEDICAL ATTENTION IF ACCIDENTALLY SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL SEEK IMMEDIATE MEDICAL ATTENTION BATTERIES PRODUCE EXPLOSIVE GASES KEEP CLEAR OF NAKED FLAMES SPARKS OR CIGARETTES VENTILATE THE AREA WHEN RECHARGING INDOORS ALWAYS WEAR EYE PROTECTION WHEN WOR...

Page 196: ...Functional inspection Hydraulic braking system Stroke of brake and clutch levers if present Clutch Check for correct operation Engine Check for correct general operation and absence of abnormal noise Other Documentation check Chassis and engine numbers check Supplied tools check License plate fitting Locks checking Tyre pressure check Installation of mirrors and any possible accessories NEVER EXCE...

Page 197: ...106 126 Electrical system 12 57 59 194 Engine oil 40 Engine temperature sensor 87 Exhaust 176 179 Exhaust manifold 179 F Filter box Fork 135 137 141 143 147 Front wheel 134 Fuel 95 109 191 Fuel pump 95 Fuses 83 H Handlebar 134 I Identification 10 Instrument panel 103 M Maintenance 8 38 Maintenance Table Mirrors 182 Mudguard 184 185 ...

Page 198: ...commended products 33 Run Stop switch 105 S Saddle Shock absorbers 151 Side stand 102 Side stand sensor 102 Spark plugs Speed sensor 84 Stand 102 Start up 81 T Tank 109 191 Throttle body 43 45 Transmission 12 39 Tyres 14 W Warning lights Wiring diagram 75 ...

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