00/2004-05

Nevada Classic 750 ie

Cod. 01 64

workshopmanual

NEVADA 750 i.e.

INTRODUCTION

SUMMARY

0.1. INTRODUCTION..... 3 0.1.1. INTRODUCTION..... 3 0.1.2. REFERENCE MANUALS.... 4 0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS... 5

NEVADA 750 i.e. 0.1.

0.1.1. -
INTRODUCTION This manual provides the information required for normal servicing. This publication is intended for use by Moto Guzzi dealerships and their qualified mechanics; many concepts have been omitted inasmuch as their inclusion would be superfluous for such an audience. Since complete mechanical explanations have not been included in this manual, the reader must be familiar with basic notions of mechanics, as well as with basic repair procedures. Without such familiarity, repairs and checks could be ineffective and even hazardous. Since the repair and vehicle check instructions are not exhaustive, special care must be taken to avoid damage and injury. To ensure maximum customer satisfaction with the vehicle, Moto Guzzi spa continuously improves its products and their documentation. The main technical modifications and changes in repair procedures are communicated to all Moto Guzzi dealerships and agencies worldwide. Such modifications will be entered in subsequent editions of the manual. In case of doubt regarding specific repairs or checks, contact the Moto Guzzi SERVICE DEPARTMENT; we will be pleased to provide all necessary information and assistance as well as keeping you updated on changes and modifications to the vehicle.
Moto Guzzi s.p.a. reserves the right to make changes to its products at any time, barring any such changes as may alter the essential features of a product as specified in the relevant manual. 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 spa is not liable in any way for the performance or use of its products. For more details see (REFERENCE MANUALS) First edition: May 2004 Designed and printed by: DECA s.r.l. via Risorgimento, 23/1 - 48022 Lugo (RA) - Italy Tel. +39 - Fax +39 - E-mail: deca@decaweb.it www.decaweb.it On behalf of: Moto Guzzi s.p.a. via E.V. Parodi, 57- 23826 Mandello del Lario (Lecco) - Italy Tel. +39 (0)341 - 709111 Fax +39 (0)341 - 709220 www.motoguzzi.it www.servicemotoguzzi.com

0.1.2. REFERENCE MANUALS

PARTS CATALOGUES guzzi part# (description) GU07500 OWNERS MANUALS guzzi part# (description) 32.90.00.60 32.90.00.61 32.90.00.62 CYCLE PARTS TECHNICAL MANUAL guzzi part# (description) 32.92.01.60 32.92.01.61 32.92.01.62 32.92.01.63 32.92.01.64 32.92.01.65 ENGINE TECHNICAL MANUAL guzzi part# (description) 32.92.02.10 32.92.02.11 32.92.02.12 32.92.02.13 32.92.02.14 32.92.02.15
0.1.3. # < > ~ C F AC A Ah API HV AV/DC bar DC. cc CO CPU DIN DOHC ECU rpm HC ISC ISO Kg Kgm km kph k kPa KS kW ABBREVIATIONS/SYMBOLS/CONVENTIONS = number = less than = greater than = less than or equal to = more than or equal to = approximately = infinity = degrees Celsius (centigrade) = degrees Fahrenheit = plus or minus = alternating current = Ampere = Ampere per hour = American Petroleum Institute = high voltage = Anti-Vibration Double Countershaft = pressure measurement (1 bar =100 kPa) = Direct Current = cubic centimetres = carbon monoxide = Central Processing Unit = German industrial standards (Deutsche Industrie Norm) = Double Overhead Camshaft = Electronic Control Unit = revolutions per minute = unburnt hydrocarbons = Idle Speed Control = International Standardization Organization = kilograms = kilogram metre (1 kgm =10 Nm) = kilometres = kilometres per hour = kilo Ohm = kiloPascal (1 kPa =0.01 bar) = clutch side (from the German "Kupplungseite") = kiloWatt = litres = racetrack lap = Light Emitting Diode = left side = metres per second = maximum = millibar (1 mbar =0.1 kPa) = miles = minimum = miles per hour = flywheel side (from the German "Magnetoseite") = megaOhm = Not Available = Motor Octane Number = Research Octane Number = Newton metre (1 Nm =0.1 kgm) = ohm = pick-up = Bottom Dead Centre = Top Dead Centre = Pneumatic Power Clutch = right side = Society of Automotive Engineers = diagnostic check = crown-head Allen screw
LAP LED LEFT SIDE m/s max mbar mi MIN MPH MS M N.A. N.O.M.M. N.O.R.M. Nm PICK-UP BDC TDC PPC RIGHT SIDE SAE TEST T.B.E.I.

HYDROGEN GAS AND BATTERY ELECTROLYTE
DANGER The battery electrolyte is a toxic, caustic substance containing sulphuric acid and thus able to cause severe burns in case of contact. Always wear tight gloves and protective clothes when handling this fluid. If the electrolyte gets in contact with the skin, carefully wash the parts of your body that get in contact with the fluid with abundant fresh water. Always use a protection for your eyes since also a very small amount of the battery fluid can cause blindness. In the event of contact with your eyes, carefully wash them with water for fifteen minutes and then consult immediately an eye specialist. Should you accidentally drink some fluid, drink abundant water or milk, then drink magnesia milk or vegetable oil and consult immediately a doctor. Battery releases explosive gases. Keep flames, sparks, cigarettes and any other heat source away from the battery. Make sure the room is well-aerated when servicing or recharging the battery. KEEP AWAY FROM CHILDREN. The battery fluid is corrosive Do not pour it on the plastic parts. Make sure that the electrolyte acid is suitable for the type of battery used. GENERAL PRECAUTIONS AND INFORMATION Follow these instructions closely when repairing, disassembling or reassembling the motorcycle or its components. DANGER Using bare flames is strictly forbidden when working on the motorcycle. Before servicing or inspecting the motorcycle: stop the engine and remove the key from the ignition switch; allow for the engine and exhaust system to cool down; where possible, lift the motorcycle using adequate equipment placed on firm and level ground. Be careful of any parts of the engine or exhaust system which may still be hot to the touch to avoid scalds or burns. Never put any mechanical parts or other vehicle components in your mouth when you have both hands busy. None of the motorcycle components is edible. Some components are harmful to the human body or toxic. Unless expressly specified otherwise, motorcycle assemblies are refitted or re-assembled by reversing the removal or dismantling procedure. Where a procedure is cross-referred to relevant sections in the manual, proceed sensibly to avoid disturbing any parts unless strictly necessary. Never attempt to polish matte-finished surfaces with lapping compounds. Never use fuel instead of solvent to clean the motorcycle. Do not clean any rubber or plastic parts or the seat with alcohol, petrol or solvents. Clean with water and neutral detergent. 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. Read (DANGEROUS ELEMENTS).

ELECTRICAL CONNECTORS To disconnect the electrical connector, follow the procedures below. Failure to comply with these procedures may lead to irreparable damages to the connector and the wiring as well. If present, press the special safety hooks. WARNING Do not pull cables to disconnect the two connectors. Grasp the two connectors and disconnect them by pulling them in the two opposite directions. In case of dirt, rust, moisture, etc., thoroughly clean the inside of the connectors with compressed air. Make sure that the cables are correctly fitted inside the connectors terminals.
NOTE The two connectors have just one correct positioning. Make sure to position them in the right direction. Then fit the two connectors. Make sure they are correctly coupled (a click will be heard).
TIGHTENING TORQUE SETTINGS DANGER Always remember that the tightening torque settings of all wheel, brake, wheel shaft and other suspension parts play a fundamental role to ensure vehicle safety. Make sure that these values are always within the specified limits. Check fastening parts tightening torque settings at regular intervals. Upon reassembly, always use a torque wrench. Failure to comply with these recommendations could lead to the loosening and detachment of one of these parts with a consequent locking of the wheel or other serious troubles affecting the vehicle maneuverability, and thus the risk of falls and serious injuries or death.

1.3.1. FUEL

DANGEROUS ELEMENTS

WARNINGS

DANGER The fuel used to operate engines is highly flammable and becomes explosive under particular conditions. Refuelling and engine service should take place in a well-ventilated area with the engine stopped. Do not smoke when refuelling or in the proximity of sources of fuel vapours. 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 engine. Fuel expands from heat and when left under direct sunlight. Never fill the fuel tank up to the rim. Tighten the filler cap securely after each refuelling. Avoid contact with skin. Do not inhale vapours. Do not swallow fuel. Do not transfer fuel between different containers using a hose. DO NOT RELEASE FUEL INTO THE ENVIRONMENT. KEEP AWAY FROM CHILDREN. Use only premium grade unleaded petrol, min. O.N. 95 (N.O.R.M.) and 85 (N.O.M.M.). LUBRICANTS DANGER A good lubrication ensures the vehicle safety. Failure to keep the lubricants at the recommended level or the use of a non-suitable new and clean type of lubricant can lead to the engine or gearbox seizure, thus leading to serious accidents, personal injury or even death. Gear oil may cause serious damage to the skin if handled daily and for long periods. Wash your hands carefully after use. Do not dispose of oil into the environment. Take it to the filling station where you usually buy it or to an oil salvage center. WARNING When filling the vehicle with this oil, take care not to spill it out since it could damage the vehicle paintwork. In case of contact with oil, the tyres surface will become very slippery, thus becoming a serious danger for your safety. In case of leaks, do not use the vehicle. Check and trace the cause of leaks and proceed to repair. 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 release into the environment. Dispose of engine oil through the nearest waste oil reclamation firm or through the supplier. Wear latex gloves during servicing FRONT FORK FLUID DANGER Front suspension response can be modified to a certain extent by changing damping settings and/or selecting a particular grade of oil. Standard oil grade is SAE 20 W. Different oil grades can be selected to obtain a particular suspension response. (Choose 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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1.4.1.

RUNNING-IN

RUNNING-IN RECOMMENDATIONS
The running-in of the engine is essential to ensure its duration and correct functioning. If possible, drive on hilly roads and/or roads with many bends, so that the engine, the suspensions and the brakes undergo a more effective running-in. During running-in, change speed. In this way the components are first "loaded" and then "relieved" and the engine parts can thus cool down. Even if it is important to stress the engine components during running-in, take care not to exceed. WARNING Only after the first 2000 km (1243 mi) of running-in you can expect the best performance levels from the vehicle. Keep to the following indications: Do not open the throttle completely if the speed is low, both during and after the running-in. During the first 100 km (62 mi) pull the brakes with caution, avoiding sharp and prolonged brakings. This ensures a correct bedding-in of the pads on the brake disc. During the first 1000 km (621 mi) never exceed 5000 rpm (see table). WARNING After the first 1000 km (621 mi), Dealer carry out the checks indicated in the column "After running-in", see (REGULAR SERVICE INTERVALS CHART), in order to avoid hurting yourself or other people and/or damaging the vehicle. Between the first 1000 km (621 mi) and 2000 km (1243 mi) drive more briskly, change speed and use the maximum acceleration only for a few seconds, in order to ensure better coupling of the components; never exceed 6000 rpm (see table). After the first 2000 km (1243 mi) you can expect better performance from the engine, however, without exceeding the maximum allowed [7600 rpm].
Engine maximum rpm recommended Mileage km (mi) 01000 (621) 10002000 (6211243) over 2000 (1243)

rpm 7600

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NEVADA 750 i.e. 1.5.

1.5.1.
LOCATION OF SERIAL NUMBERS
These numbers are necessary for vehicle registration. IMPORTANT: Altering the identification numbers of vehicle or engine is a legal offence punishable by heavy fines and penalties. In addition, altering the frame number (VIN) results in immediate warranty invalidation. The serial number is composed of numbers and letters as shown in the following example. ZGULM00004MXXXXXX.

Part number 64 60

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2.1.6.

LOCATION OF MAIN PARTS
Key: 1. Headlight 2. Left rear-view mirror 3. Fuel filler cap 4. Fuel tank 5. Left side fairing 6. Main fuse-holder (30A) 7. Battery 8. Rider/pillion seat 9. Pillion grab handle 10. Rear left damper 11. Pillion left footpeg 12. Seat lock 13. Rear swing arm 14. Side stand 15. Rider left footpeg 16. Gear shift lever 17. Engine oil dipstick 18. Left horn

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Key: 1. Tail light 2. Rear brake fluid reservoir 3. Secondary fuseholders 4. Glove/tool kit compartment 5. Right side fairing 6. Right rear-view mirror 7. Front brake fluid reservoir 8. Air cleaner 9. Right horn 10. Engine oil filter 11. Rear brake lever 12. Rider right footpeg 13. Engine Control Unit 14. Rear brake master cylinder 15. Pillion right footpeg 16. Driveshaft transmission 17. Right rear damper

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2.1.7.
LOCATION OF CONTROLS / INSTRUMENTS
Key: 1. Clutch lever 2. Ignition switch / steering lock ( 3. Instruments and indicators 4. Front brake lever 5. Throttle twistgrip 6. High beam flasher button ( ) - ) 7. Lights selector ( 8. 9. 10. 11. 12. Choke lever ( ) Direction indicators switch ( ) Horn button ( ) Engine cut-out switch ( - ) Starter button ( )
Key: 1. Direction indicator warning light ( ) green 2. High beam warning light ( ) blue 3. Engine oil pressure warning light ( ) red 4. Fuel reserve warning light ( ) amber yellow indicator light, red 5. 6. Neutral gear warning light (N) green 7. Rev counter 8. Hazard lights button ( ) red 9. TRIP button (multifunction display) 10. Multifunction digital display 11. Speedo

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NEVADA 750 i.e. 2.2.

2.2.1.

MAINTENANCE OPERATIONS
ENGINE OIL AND FILTER CHANGE
ENGINE OIL CHANGE IMPORTANT Oil flows more easily when warm. Let the engine warm up for about twenty minutes to facilitate total drainage. Place a container of capacity greater than 4000 cm3 (244 in3) under the drain plug. Unscrew and remove the drain plugs.
Unscrew and remove the filler plug. Drain the oil into the container allowing the last of the oil drip out for several minutes. Inspect the sealing washer of the drain plugs and replace if necessary. Clean off any metal debris sticking to the drain plug magnet. Refit and tighten the drain plugs.

22 DASHBOARD AIR TEMPERATURE SENSOR resistance 32510 (temperature 0C + 2% 32F + 2%) resistance 9960 (temperature 25C + 3% 77F + 3%)

5.1.2. ECU CONNECTIONS

ECU SIDE
PIN DESIGNATION Throttle position sensor power supply Lambda sensor signal (ground) Rev counter control Cylinder head air temperature sensor signal Right-hand injector control Engine speed sensor Lambda sensor signal (positive) Diagnostics line (K) Diagnostics line (L) Throttle position signal Engine speed sensor Right-hand injector control Right-hand coil control Injection indicator light control Bank angle sensor signal Engine control unit power supply Intake air temperature sensor signal Injection relay control Left-hand coil control Sensors power supply (ground) Engine control unit power supply (ground) Engine control unit power supply (ground) Engine control unit power supply (+15) SIGNAL TYPE Power output Analog input Frequency output Analog input Power output Frequency input Analog input Communication line Communication line Analog input Frequency input Power output Power output Digital output Digital input Power input Analog input Digital output Power output Power output Power input Power input Power input

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5.1.3. WIRING DIAGRAM

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Key: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. WIRE COLOURS: Ar Orange Az Light blue B Blue Bi White G Yellow Gr Grey M Brown N Black R Red V Green Vi Violet Ro Pink
Multiple connectors RPM sensor Oil pressure sensor Left coil Right coil Spark plugs Left injector Right injector Fuel pump Low fuel sensor Main inj. relay (Polarised) Secondary injection relay Side stand switch Oxygen sensor Throttle sensor Engine air thermistor Head T sensor Voltage regulator Flywheel Battery Starter motor Main fuses Auxiliary fuses Number plate light Rear left turn indicator Stop - parking light Tail light Rear right turn indicator Key-operated switch Front stop light switch Rear stop light switch Right dimmer switch Left dimmer switch Warning horn Clutch switch Starter relay Horn diode Antitheft system LED connector Diode Neutral switch Bank angle sensor Instrument panel Speed sensor Instrument panel air T thermistor Front right turn indicator High - low beam bulb Front parking light bulb Headlight Front left turn indicator E.C.U. Diagnostics socket

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TRANSMISSION
6.1. SWING ARM COMPLETE WITH TRANSMISSION ASSY... 3 6.1.1. REMOVAL..... 3 6.1.2. INSPECTION..... 8 6.1.3. REASSEMBLY..... 9 6.1.4. TIGHTENING TORQUES.... 12 6.2. TRANSMISSION CASE.... 13 6.2.1. REMOVING THE PINION HOUSING... 13 6.2.2. INSPECTION..... 16 6.2.3. REASSEMBLY..... 17 6.2.4. TIGHTENING TORQUES.... 20 6.3. DISASSEMBLING THE TRANSMISSION CASE... 21 6.3.1. DISASSEMBLING THE TRANSMISSION CASE... 21 6.3.2. INSPECTION..... 24 6.3.3. PINION GEAR MESHING (BEVEL GEAR SET)... 25 6.3.4. REASSEMBLY..... 28 6.3.5. TIGHTENING TORQUES.... 32 6.4. REAR SWING ARM..... 33 6.4.1. DISASSEMBLY..... 33 6.4.2. INSPECTION..... 37 6.4.3. REASSEMBLY..... 38 6.4.4. TIGHTENING TORQUES.... 40

NEVADA 750 i.e. 6.1.

6.1.1.
SWING ARM COMPLETE WITH TRANSMISSION ASSY
REMOVAL Remove the left silencer.
Remove the rear brake caliper, release the brake line from the swingarm fastener.
Loosen and remove the brake caliper holder screw.
Remove both rear suspensions.
Loosen and remove the nut, collect the washer.
Loosen the screw securing the wheel shaft.
Remove the wheel shaft, collect the spacer.

Remove the rear wheel.

Loosen the tie. Remove the protection.

Loosen the nuts.

Loosen the shafts so that the swingarm can be detached from the gearbox.
Remove the shim between swingarm right section and gearbox.
Unscrew the four nuts and recover the washers.
Remove the complete transmission case from the swing arm.
Remove the sleeve from the pinion. Remove the spring. Remove the seal ring. Remove the cap.

Withdraw the gear.

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 necessary. 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.
6.1.3. REASSEMBLY Equip the transmission case bevel pinion with the sleeve and cap
Fit the transmission case studs correctly into the corresponding holes in the swing arm.

Snug the tightening.

Use the specific punch (19926100) to drive the complete pinion into the housing.
Fit the oil seal; Fit the O-ring.

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Fit the distance collar.
Insert the splined shaft of the pinion in the special tool (19907100) and tighten the nut.

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6.2.4. TIGHTENING TORQUES
REAR TRANSMISSION Bevel pinion to case fixing nut Bevel gear to hollow shaft fixing screws Cover to transmission case fixing screws 100 Nm 42 Nm 25 Nm

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NEVADA 750 i.e. 6.3.

6.3.1.

DISASSEMBLING THE TRANSMISSION CASE
DISASSEMBLING THE TRANSMISSION CASE Unscrew the screws and set the washers aside.
Remove the brake disk from the hollow shaft. Unscrew the screws and set aside the square washers and spring washers. Remove the complete cover. Remove the gaskets. Remove the spacer.
Remove the circlip from the groove in the hollow shaft.

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Remove the following parts from the cover: The roller bearing. Use the specific punch (19907000) to drive out the taper roller bearing inner race. Remove the washer. Remove the washer.
Unscrew the screws and set the locking tabs aside;

Remove the bevel gear

Withdraw the hollow shaft from the bearing.

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Remove the seal ring.
Use the specific punch to drive the bearing out of the cover.
Use the specific puller (19927500) to remove the taper roller bearing outer race from the transmission case.
Remove the seal ring and the washer.

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6.3.2. INSPECTION Check that the fins of the hollow shaft subject to the action 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 excessively 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, otherwise renew; Check that the roller bearing on the transmission case shows no signs of out of round or worn rollers, otherwise, 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.

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6.3.3. PINION GEAR MESHING (BEVEL GEAR SET)

Perform these operations to mesh the pinion and gear: Use two nuts and suitable spacers to temporarily secure the housing complete with pinion to the transmission case; Fit the specific tool (19928800) to the gear.
Insert the tool onto the transmission case roller bearing.
Check the alignment between the pinion teeth and the gear teeth; If the teeth are not properly aligned adjust the thickness of the ring interposed between the pinion and the taper roller bearing. You must also check the contact area between the pinion teeth and the gear teeth as follows:
Coat the pinion teeth with a specific commercial marker dye.

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Fit the gear-hollow shaft assy., cover and relative spacers and gaskets to the transmission case and temporarily screw down the fixing screws.
Equip the gear holder hollow shaft with a Universal puller tool having central spacers in such a way as to maintain the gear so that it exerts slight pressure towards the brake disk side. Turn the pinion in the direction of run while braking the gear so that the rotation takes place under load and the contact areas are marked on the pinion tooth surfaces.
If the contact is correct the marking on the pinion teeth should appear as shown. Note that the pinion is viewed from the driving shaft side
If the contact markings are as shown here, the gear is too close to the pinion axis of rotation: move the gear back by increasing the thickness of the shim

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If the contact markings are as shown here, the pinion is too close to the gear axis of rotation: move the pinion backwards by reducing the thickness of the shim
If the contact markings are as shown here, the pinion is too far from the gear axis of rotation: move the pinion forwards by increasing the thickness of the shim.
If the contact markings are as shown here, the gear is too far from the pinion axis of rotation: move the gear forwards by reducing the thickness of the shim.

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6.3.4. REASSEMBLY Fit the washer on the transmission case.
Use the specific punch (19926000) to fit the seal ring on the transmission case.
Use the specific punch (19926500) to fit the roller bearing outer race to the transmission case.

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Use the specific punch to fit the bearing to the cover.
Use the specific punch (19927900) to fit the roller bearing inner race to the hollow shaft; Fit the seal ring to the hollow shaft.
Assemble the hollow shaft to the cover.

Fit the gear.

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Insert the square locking tabs and tighten the screws.

7.1.2. FORK LEG REMOVAL

The motorcycle is equipped with a non-adjustable fork. The procedures described below apply to both the fork legs. WARNING During the following procedures, the legs and their internal components must be clamped in a vice. Take great care not to damage them by overtightening; always use aluminium jaw coverings Place the motorcycle on a stable stand so that the front wheel is lifted from the ground. Remove the front brake calliper without disconnecting the brake fluid line.

Remove the front wheel.

Remove the front mudguard.
Working on either side, remove the plastic rivet.
Remove the instrument panel protection.
Loosen and remove the two screws, collect the washers.
Loosen and remove the nut under the instrument panel, collect the washer.
Move the instrument panel forward.
Unscrew the two lower clamping screws

Loosen the lower screw.

Slide out the fork leg downwards while rotating it first in one direction then in the opposite direction.
7.1.3. OVERHAUL Use new gaskets during reassembly after complete disassembly. Use a non-inflammable and preferably biodegradable solvent for cleaning. Lubricate all the contact surfaces before reassembly. Always smear grease on the seal ring lips before reassembly.

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

Oil leakage from the seal ring
1. Worn seal ring 2. Scored stanchion 3. The ring is dirty 1. Defective foot gasket 2. The foot screw is loose 1. Low oil level 2. Defective spring 3. Oil viscosity too low 1. Oil level too high 2. Oil viscosity too high

SOLUTION

1. Replace the seal ring 2. Replace stanchion and ring 3. Clean or replace 1. Replace gasket 2. Tighten screw 1. Restore correct fork oil level 2. Replace spring 3. Change oil with oil of correct viscosity 1. Restore correct fork oil level 2. Change oil with oil of correct viscosity
Oil leakage from the bottom Fork suspension too soft
Fork suspension too stiff
7.1.5. FRONT FORK OIL CHANGE
IMPORTANT The following procedures apply to both legs. The fork oil must be changed periodically, see (PERIODIC MAINTENANCE TABLE). IMPORTANT During oil drainage and filling operations, the fork leg and its internal parts must be clamped in a vice; take care to avoid damaging the parts by overtightening; always use aluminium jaw coverings. OIL DRAINAGE To drain the oil follow the procedures described below: Disassemble the fork leg.

Check that the slider is equipped with the upper guide ring.
Fit the lower sliding bushing in the seat on the stanchion.
Now reassemble the stanchion tube and slider.

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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.
Place the retainer and the well-lubricated seal ring on the stanchion tube. Push the seal ring fully home inside the slider by using the specific inserter tool.
Install the retaining ring.

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Install the wiper seal. Pour oil into the stanchion ensuring that it also fills the internal passages of the plunger rod. Pump the stanchion up and down to ensure the plunger rod is completely filled with oil. Insert the spring and preload tube. Fit the plug on the stanchion tube taking care not to damage the O-ring. Tighten the plug to the prescribed torque.

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7.1.9. REASSEMBLY OF THE FORK LEG Fit the fork leg to the motorcycle, passing it through the lower plate and the upper plate.
Tighten the screws to the prescribed torque.

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7.1.10. TIGHTENING TORQUES
FRONT SUSPENSION Centre stand to frame fixing screws Lock nut Fork head fixing screws Fork base fixing screws Slider to wheel spindle fixing screws 10

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NEVADA 750 i.e. 7.2.

7.2.1.

ADJUSTING PLAY IN THE STEERING BEARINGS
ADJUSTING PLAY IN THE STEERING BEARINGS Remove the handlebars Remove the dashboard
Working on both sides, unscrew and remove the screw that secures the top plate to the front forks
Unscrew and remove the central nut

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Remove the top plate from the front fork
Adjust the ringnut Position the top plate on the front fork

Tighten the central nut

Working on both sides unscrew and remove the screw that secures the top plate to the front forks Fit the handlebars Fit the dashboard.

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7.2.2. TIGHTENING TORQUES
STEERING Steering head fixing screw 50 Nm

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CYCLE PARTS 7.3.

7.3.1.

REAR SUSPENSIONS
REMOVING THE REAR SUSPENSION Loosen the screws securing the suspension guards to the frame. Remove the suspension guards.

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Loosen the suspension lower screw.
Remove the suspensions from the shafts.

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7.3.2. INSPECTION Check the condition of the springs and the dampers (always 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 that the flexible bushes on the struts for possible degradation or hardening and renew if necessary. If you notice irregularities in the cushioning action of the dampers, they must be renewed. CAUTION To ensure good stability of the motorcycle, both the suspension springs must be adjusted to the same position.

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7.3.3. REFITTING THE REAR SUSPENSION Position the suspension to shafts.
Tighten the rear suspension lower screw.
Refit the suspension guards.
Tighten the screws securing the suspension guards to the frame.

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7.3.4. TIGHTENING TORQUES

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Moto Guzzi S.p.a. Via E.V. Parodi, Mandello del Lario (LECCO) Italy Tel. +709111 Fax +709220 www.motoguzzi.it www.servicemotoguzzi.com