Contents

Breva 1100
Æ Aspects and vehicle characteristics
Æ General data
Æ Dashboard and immobilizer
Æ Electronic injection, description and functioning
Æ Engine
Æ New electro-mechanical components
Æ Diagnosis - Axone
Æ Balancing throttle bodies

1
Aspect and vehicle characteristics

2
Aspect and vehicle characteristics
Total view of vehicle :
dimensions

3
Aspect and vehicle characteristics
General data

Weight: 248 Kg

Output: max. KW 63,0 at 7500 rpm

Torque: Nm 85,0 a 6800 rpm
Maximum speed in 6th gear 210 Km/h

Front tire: 120/70 ZR17 (58W) pressure 1/2 persons 250kPa±10

Rear tire: 180/55 ZR17 (73W) pressure 1/2 persons 280kPa±10

Injection/ignition system MAGNETI MARELLI

Computer IAW 5AM2 with map alfa/n

4
Aspect and vehicle characteristics

Frame
ZGULP...

5
Aspect and vehicle characteristics
Fuel tank

Fuel pump

Capacity 23 l ± 0,5 l
Material Nylon

6
Aspect and vehicle characteristics
Front brakes Rear brakes
Double calipers and discs

7
Aspect and vehicle characteristics
Additional equipment.
Accessories (optional):
- Windscreen;
- Carrying Case adjustable in height;
- Side bags
- Alarm systems (not yet available)

8
Dashboard

9
Dashboard : identifying areas

Rev counter:
Positioned at the left, final range 10.000 rpm.

At the end of the scale is a red warning light (Led) without

monogram to indicate to shift gear when surpassing a preset
level rpm. The rpm activation level can be adjusted via the users
interface.

10
Dashboard : identifying areas
Speedometer at the center

Fuel level
indicator Under
the fuel warning
light sits a red
warning light
without pictogram
(Led) for the
eventual alarm
system.

Multifunctional Display

11
Dashboard : identifying areas

Fuel level indicator

The dashboard is connected to a variable resistor. Measurements that fall out of the
normal operating range are considered as faults and are signalled by the diagnostics.
The indications show at the instrument panel at the right and the spare indicator
underneath.
The characteristics and measurement curve can be found in the repair manual.

• Quantity LITRES OHM

• 8/8 22.50 10-20 appr.
• 4/8 11.25 100 appr.
• 0 0 250-300 appr.
The spare indicator lights up at values higher than 230 ohm
After 2 km it shows the amount of km driven after the indicator light
came on.

12
Dashboard : identifying areas
Led indicators

From left to right:

- Indicator green, left hand indicator
- Indicator orange, ABS faulty (CURRENTLY NOT ACTIVE)
- Indicator red, Alarm: engine oil pressure problem, EFI and w/ vehicle OFF indicator
immobilizer.
- Indicator green, Neutral position
- Indicator yellow, vehicle stand down
- Indicator blue, beam lights on
- Indicator green, right hand indicator

13
Dashboard: indicators and lights
Direction indicators.
• The dashboards controls the indicator lights, as well for the single indications left
and right as for the combined circuits for the “Hazard” function.

• Indications for problems with circuits ( bulb burnt or short circuited) by doubling the
flashing frequency of the warning light and with indication on the dashboard left or
right

Activation/deactivation of the Hazard function

This function can only be activated or deactivated with the key in ON position

Control of beam lights

The light relay will only be operated by the engine ECU when the rpm exceeds 800

14
Dashboard: selections
The commands to move between various dashboards functions are obtained by a three
position selector at the light switch at the left hand steering handle.

The selector has following

three positions:
- Trip 1
- Trip 2
- Mode

In the first position will show the data of TRIP1,

In the second the data of TRIP2
While in the third position MODE, one can access to the functions of dashboard
configurations.

15
Dashboard: display
Basic information

•On the display appear as well the basic information as the information activated by the
selector position. These are:
•Clock. Clock settings can be 12 or 24 hour indications, where 12 hour indications
show AM or PM.
•Odometer. A 6 digit number in km or miles, according to user selection.
•Ambient temperature. Shows in the upper left corner of the LCD. When the temperature
is close to zero, a icing symbol will show (next slide). Finally one can show the
temperature in °C or °F selectable by the user.

Clock Display

16
Dashboard: display

Handles heater (OPTIONAL)

With engine running, by pressing insisting at command handles heating, an icon will
show at the display that substitutes the selected trip indication. That will be transferred to
the central part of the display. With every short pulse a three positions bar will grow
indicating the power level present in the handles heating. When the engine is stopped the
heater will be switched off. At the next vehicle usage the handles heater will reposition at
the ultimate setting.

17
Dashboard: immobilizer

Ä The immobilizer system is integrated in the electronic dashboard.

Ä At key-to-ON the dashboard will read the key code. If the code corresponds to the
one memorized, the dashboard will activate the initial check and will allow the
ECU for engine starting, via the CAN Bus line.

Ä If the key code is not recognized, the dashboard will not permit for engine starting
and on the display will appear the request to insert the code to allow for
“manually” engine starting.

Ä To the customer will be delivered two keys with transponder, already memorized
from the factory and at every key-to-ON the dashboard will ask to insert the
personal 5 digit code, if not yet done:

you must remember to insert the user code

Ä To insert the personal code one must select the function CODE MODIFICATION

18
Dashboard : display
Trip 1-2
In these two positions of the display are demonstrated the data relevant for
trips 1 and 2.
In the central area is constantly displayed the partial distance covered while in the
lower portion the following data will be shown in rotation:
•Trip time
•Average Fuel consumption of the trip
•Current consumption
•Maximum speed
•Average speed
A short pulse will change the indications between one and the other, keeping the
switch pressed longer will reset all values to zero for the selected trip.
Consumption is expressed in litres per 100 kilometres or in miles per gallon

For detailed functioning please read with attention the workshop manual information.

19
Dashboard : MODE
Mode
in this position you can select the other functions of the dashboard with the vehicle
stopped and thus with speed equal to Zero with every short pulse of the switch SET you
can see in sequence the following functions:
stopwatch battery voltage Menu
The selection of the functions is affected by holding the SET switch for a longer period.

For detailed functioning of the stopwatch please read with attention the workshop manual

20
Dashboard :Menu

Access to this function is only possible with the vehicle stopped .The graphic of this menu is
as follows:

To move your selection down-wards,a short pulse of the switch is sufficient

Pressing the switch down for longer gives the confirmation of your selection of the
relative item.

21
Dashboard : Settings

SETTINGS
When the settings menu is selected, which can also be done by the driver or bike owner, a
drop-down menu shows:
Exit
Adjust Clock
Change gear shift rpm
°C/°F
12H/24/
Led immobiliser (turn off when installing the optional alarm system)
Change code
Recover code
For detailed functioning please read with attention the workshop manuals

22
Dashboard : Settings
Change CODE
In case one remembers its own code is sufficient to insert it and in sequence we will
insert the new code which will automatically be memorised.
In case of a new vehicle the user code is: 00000

Recover CODE
In case one does not remember it own code and wishes to modify it, it is requested to
insert the two keys that are memorised. The first one is already inserted and therefore it is
requested to insert the second key with the message: INSERT 2ND KEY
If the second key is not inserted within 20 seconds the operation will terminate.
After its recognition it will be requested to insert a new code with the message:
INSERT THE NEW CODE
At the end of the operation the dashboard will return to the menu Settings.

23
Dashboard: DIAGNOSTICS
DIAGNOSTICS
To enter in this menu, that will operate on the diagnostic functions and therefore the
access is reserved to the technical assistance, a code is requested.
Appears the text: INSERT SERVICE CODE

For the Breva 1100 this is: 36421

The functions in this menu are:
Exit
Faults ECU
Faults dashboard
Cancel Fault codes
Reset Service
Update
Change keys

24
Dashboard : DIAGNOSTICS
FAULTS ECU. The dashboard receives from the central computer only actual faults
Description Error code
Error throttle valve C.C. Vcc ECU 10
Error throttle valve C.C. Gnd ECU 11
Error Engine temperature C.C. Vcc ECU 14
Error Engine temperature C.C Gnd ECU 15
Error Air temperature C.C. Vcc ECU 16
Error Air temperature C.C Gnd ECU 17
Error Low battery ECU 20
Error Lambda sensor ECU 21
Error Ignition coil 1 C.C. Vcc ECU 22
Error Ignition coil 1 C.C. Gnd ECU 23
Error Ignition coil 2 C.C. Vcc ECU 24
Error Ignition coil 2 C.C. Gnd ECU 25
Error Injector 1 C.C. Vcc. ECU 26
Error Injector 1 C.C. Gnd ECU 27
Error Injector 2 C.C. Vcc ECU 30
Error Pump relay ECU 36

25
Dashboard : DIAGNOSTICS

FAULTS ECU. The dashboard receives from the central computer only actual faults
Description Error code

Error Local Loop-back ECU 37

Error relay starter C.C. Vcc ECU 44

Error relay starter C.C. ground ECU 45

Error cannister C.C Vcc ECU 46
Error cannister C.C. ground ECU 47
Error battery high ECU 50
Error ECU general ECU 51
Error instrument panel ECU 54
Error autoadaptation Tito I ECU 55
Error vehicle speed ECU 56
Error stepper C.A. ECU 60
Error stepper C.C. Vcc ECU 61
Error stepper C.C. Ground ECU 62
Error unknown ECU 00

26
Dashboard : DIAGNOSTICS
DASHBOARD ERRORS
In this mode a table lists eventual mistakes of the immobiliser and its connected sensors.
The error codes are explained as follows

Description Error code

Immobiliser fault: key code read but not recognised DSB 01
Immobiliser fault: key code not read
(key not present or transponder broken) DSB 02
Immobiliser fault: Antenna broken (open or short-circuit) DSB 03
Immobiliser fault: internal controller fault DSB 04
Fuel sensor fault DSB 05
Air temperature sensor fault DSB 06
Oil sensor fault DSB 07
Oil pressure fault DSB 08
The dashboard maintains memory of old errors.

27
Dashboard : DIAGNOSTICS

CANCEL ERRORS
With this option only dashboard faults are erased. A final confirmation will be requested.

Reset service
This function allows to reset the service interval indicator. For the end of line testing
purposes this operation also has the possibility for one time only to set the odometer to
zero if done within the first 200 kilometers

28
DIAGNOSIS DSAHBOARD

Update
This function allows to reprogram the dashboard with new software via Axone.
On the display appears: “dashboard disconnected”.it is now possible to connect the
diagnostic tool ; the dashboard will be reconnected normally after a key OFF/ON
operation
Currently there is no new software

The white connector is underneath the

saddle besides the fuse box close to the
diagnostic connector of the injection
system.

To connect Axone it is necessary to use

the connector Ditech which is present at
the confection of Axone 2000 Aprilia-
Moto Guzzi

29
Dashboard : DIAGNOSTICS

Function MODIFY KEYS

Ä This function can be used:

1) in case of key loss, the dealer can cancel the lost key
2) to activate up to 4 keys
3) if necessary use a new key ignition lock and memorise a new
set of keys.

in the first phase it is requested to insert the user code and after
giving confirmation that the key is memorised (1st key), it is
requested to insert the other keys .
The procedure ends after four keys are memorised or after 20
seconds

30
Dashboard : DIAGNOSTICS

Function CHANGE KEYS

Ä In case of the use of a new ignition key set, details of the

procedure are as follows:
Ä Once turned the key to ON the dashboard not recognising the key
will ask for the user code: insert the user code.

Ä At this point one can enter in MENU, DIAGNOSIS( inserting the

service code) CHANGE KEYS and start the procedure of
memorising the new keys.

31
Dashboard : DIAGNOSTICS

Indication of service interval

When nearing service interval mileage a small wrench will appear in the display.
This will be at the same position as the ice symbol.
This indicator can be reset starting 300 kilometers prior to the service interval, in
this 300 kilometer range the indicator will normally blink five seconds and then
go off.

First time showing at 1500 kilometers, following activation every 10.000

kilometer

32
Dashboard : visualise warnings

The dashboard shows to the driver in the lower portion of its

display the following alarms by keeping the red warning light on:

Oil level

Errors from computer or dashboard SERVICE

Communication faults with the ECU

example:

33
Dashboard: DIAGNOSTICS
Engine oil sensor faults
The dashboard will reveal oil pressure faults as well as sensor faults. The oil
sensor fault is detected with engine stopped and key in on position, if the
sensor is not conducting (open circuit). This fault is indicated by lightening
the warning “service” that will remain lit also with engine running

Abnormal oil pressure is indicated with engine running at an rpm higher than
2000 rpm and the sensor conducting (shorted). In this case the fault is
indicated by lightning the icon “oilcan”.
In both cases codes are stored in the diagnostic memory of the dashboard

34
Dashboard : connections
PIN SERVIZIO PIN SERVIZIO
1 +KEY 11 +BATTERY
2 COMAND RH INDICATOR 12 COMAND LH INDICATOR
3 OIL SENSOR 13 RESET INDICATORI/LED ANTITHEFT
4 BEAM LIGHTS IN 14 HAZARD
5 - 15 LED ANTI THEFT (if connected)
6 SELECT 1 16 SELECT 3
7 SELECT 2 17 SENSOR GROUND
8 FUEL LEVEL SENSOR 18 GENERAL GROUND
9 AIR TEMPERATURE SENSOR 19 GENERAL GROUND
10 - 20 GENERAL GROUND
PIN SERVICE PIN SERVICE
21 + BATTERY 31 -
22 + BATTERY 32 -
23 ACTIVATE RELAYBEAM LIGHTS 33 -
24 - 34 ACTIVATION INDICATOR REAR.RH
25 COMMAND HANDLE HEATER 35 ACTIVATION INDICATOR FRONT.RH
26 CAN L 36 ACTIVATION INDICATOR REAR.LH
27 CAN H 37 ACTIVATION INDICATOR FRONT.LH
28 K-LINE 38 ACTIVATION HANDLE HEATER LH
29 - 39 ACTIVATION HANDLE HEATER RH
30 ANTENNA 1 40 ANTENNA 2

35
Engine

36
Engine: principle characteristics

Max output. KW 63,0 at 7500 rpm

Torque: Nm 85,0 at 6800 rpm

Idle speed: 1100 ± 100 giri/min

Intake valve lift: 10,74 mm

Exhaust valve lift: 10,74 mm
Gap (clearance) intake valve 0,15 ± 0,02 (inspect at 1000 km and every 10.000 km)
Gap (clearance) exhaust valve 0,2 ± 0,02 (inspect at 1000 km and every 10.000 km)

Generator with permanent magnet (alternator) with nominal power of 550 watt.

37
Engine: principle characteristics

From a technical point of view the engine is very similar to the one already installed
to the V11.
A series of optimisations and improvements of single components have been
Implemented.

Principal novelties are:

• alternator (is explained later in ELETTROMECHANICAL COMPONENTS)
• oil circuit with pressure valve and external oil filter
• valve retainer with three grooves to allow rotation for even wear of the valve
• longer drive shaft (4 mm)
• new 1st piston ring with L-shape to reduce blow-by gas
• cylinder head and base gasket metallic
• sintered valve seats
• two spark plugs per cylinder (is explained later in IGNITION COMPONENTS)
• new aspect cylinder head covers
• new gearbox

38
Engine: Lubrication group

The circuit is partially redesigned.

The pressure valve is now installed prior to the filter, in case of over pressure
(valve opened), circulates the oil to the intake of the oil pump instead of
release the oil to the crankcase, avoiding unwanted emulsing.
The oil filter is now accessable from the outside (exchange every 10.000 km like V11)
A strainer is introduced that improves the intake in any vehicle position and provides
particles filtration

The oil level needs to be checked with the dipstick NOT

fixed, different from V11, every 1000 km

Every 5000 km the drainage tube from the air filter

housing needs to be emptied

39
Engine: Lubrication group

Recommended Engine Oil: Agip RACING 4T 5W-40

Recommended Gear box Oil : Agip ROTRA MP/S 85 W 140

Cardan Oil : TRUCK GEAR 85 W 140

Do not insert
Chemical additives
Nor non recommended
Oils

40
Engine: Lubrication group
Circuit with oil pressure valve open

Thermostatic
valve

filter
Oil cooler

To the banks

Pump delivery Oil pressure valve

Pump intake

From the strainer

41
Engine: Lubrication group

Thermostatic
valve Oil pressure valve

filter

To the rear banks

oil cooler

strainer

42
Engine: Lubrication group

oil cooler

strainer

To rear banks
filter

43
Engine: oil filter

Oil filter

44
Engine: gearbox

6 speed gearbox with straight sliding gears and flexible coupling

The gears are mounted on roller bearings

The new pre-selector allows for a softer shift thanks to the desmodromic drum mounted
on bearings

The flexible coupling contains an undulated washer that needs to dampen the vibrations at idle
(noisy) while the 8 cup springs allow a gradual transmission of the engine torque
as well in engagement as disengagement.

45
Engine: gearbox
Desmodromic drum

preselector

Secundary shaft
Friction push rod

3 forks
Friction shaft

Primary shaft

46
Engine: gearbox

Undulated washer

Primary reduction idle gear with helical teeth

47
Engine: gearbox

Attention, the neutral switch needs

To be removed before extracting
The desmodromic drum when
Disassembling. In phase of
Reassembly it should be installed
At the end of the procedure

Oil level is not checked based

on a level measurement, but on
the correct amount:
500 cc

48
Transmission gear

49
Transmission gear: principle
characteristics

50
Pinion housing

Oil bleeder
plug
Characteristics:
Check and change oil

Oil filler and level

plug

Oil drain plug

51
Pinion housing : oil

52
Transmission gear: disassembly and
assembly
The assembly/disassembly operations are related to the replacement of the rubber
covers 6 and 14 and the washer 10.

53
Transmission gear: disassembly and
assembly

54
Transmission gear: disassembly and
assembly
Relative to the rotating axle are replaceable only the 2 bearings with universal
pullers.
Reassembly is effected heating both bearings to 100° C

55
Transmission gear: disassembly and
assembly
For the pignon group we can only replace the sealer with its respective holder

56
Transmission gear: disassembly and
assembly
The support group is completely replaceable.

57
Transmission gear: special tools

Support housing
Tampone tenuta asse ruota
Manico
Tampone snodo sferico
Spanner sealer pignon
Tampone tenuta ghiera pignone
Support transmission gear

58
Electronic injection

59
Electronic injection 5AM 2
DESCRIPTION INJECTION-IGNITION SYSTEM
General information on injection-ignition system
The injection and ignition system with electronic integrated control allow to
optimize performance and operation of the engine, reducing the specific
consumption and polluting elements in the exhaust gas.
With these systems, as a matter of fact, is guaranteed an optimal report
between air and fuel and ignition timing advance management

60
Electronic injection
Effect of the relation air to fuel and ignition timing advance

Î The correct management of the relation between air and fuel and the ignition timing
advance is the basis of the optimal functioning of the engine.
The ideal relation between air and fuel is the stechiometric relation in weight, which
determines the complete combustion

insufficient air or air in access will create a rich or lean mixture, which will influence
output and consumption as well as emissions in the exhaust. The electronic ignition
advanced control allows to optimize the performance of the engine, create maximum
output, reduce fuel consumption and polluting elements in the exhaust gas.
The electronic ignition advanced control integrated with the injection control, allows to
realize the best functioning of the engine in all conditions of its use ( starting at low-
temperature, phase of warming up, transitional phase of acceleration and deceleration,
engine in conditions of partial load, full load and idle speed)

61
Electronic injection
The computer is an electronic unit of the digital type with microprocessor .To
realize optimal functioning of the engine, via a series of sensors, functioning
and condition of the engine are continuously monitored.

The principal sensors are:

- Engine RPM sensor measures the number of revolutions of

the engine and the phase of each
cylinder with respect to TDC
-Throttle position sensor: measures the opening angle of the
throttle valve

Secondary or correction sensors are:

- Pressure sensor (in dashboard): measures barometric pressure

- Air temperature sensor: measures intake are temperature
- Engine temperature sensor: measures engine temperature

62
Electronic injection 5AM 2
Actuator control is determined by the information received from the sensors:
- amount of fuel injected to each cylinder in sequential mode and not parallel, by
controlling the opening time of the injectors and thus also injection timing is
referred to the intake stroke of each cylinder
- ignition timing advance (ignition coil)

Principal novelty on the system of injection with computer Marelli 5AM 2l lies in
the control of idle speed that is affected by a stepper motor that allows air to
enter in the combustion chamber by-passing the throttle valve.

Its position is modified by the computer to maintain idle speed stabilized, in

function of environmental conditions (engine temperature, air temperature,…)

63
Electronic injection : fuel circuit

Fuel tank: capacity l 23 ± 0,5 l

The fuel pump group that is positioned in the fuel

tank contains:

- fuel level indicator sensor

- fuel filter
- fuel pressure regulator
nominal pressure value 3bar

- power supply 12V

64
Electronic injection : fuel circuit
Injectors
The command sent by the computer is of the
pulsating type. This will determine the
movement of the center part of the solenoid,
revealing the opening of the injector

With a constant fuel pressure determined by

the regulator, present on the pump, of 3±0,2
bar, the quantity injected depends exclusively
of the opening time of the injector

Power supply 12V

Resistance 14 Ω ± 2 at 20°C

65
Electronic injection : fuel circuit
Pay attention to the position of the fuel tube from fuel tank to injectors that
needs to run aside the air filter not underneath

66
Electronic injection : intake air

- Air temperature sensor NTC installed in air filter housing

°c kohm
-40 100.950
-0 9.750
+10 5.970
+20 3.750
+30 2.420
+40 1.600
+90 0.280

67
Electronic injection : intake air

Potentiometer throttle valve

This sensor informs the computer about
the position of the throttle valve. The
mechanical degrees are transferred into an
electrical signal under the form of voltage.
In function of this signal the computer
foresees to adjust the time of injection to
optimize the stechiometric report.

Connector with three wires:

Power supply 5V
Ground provided by computer
Valve position signal, scale:
Appr. from 0,55 (at stopper) to
4,4 V( max. opening)

68
Electronic injection :computer 5AM 2

Located in front underneath the fuel tank has to connectors

Connector A - from 1 to 38 pin Connector B - from 1 to 38 pin

69
Electronic injection :computer 5AM 2
Connections Engine Computer

1* 20 power supply 5V (sensors NTC)

2* 21*
3 TPS signal 22*
Connector A
4* 23 neutral signal
5 Engine temperature sensor 24*
6* 25 RPM sensor signal
7* 26*
8* 27*
9 stepper motor + 28 Injector cylinder lh.
10 command ignition coil rh. 29 Power-supply TPS sensor.
11* 30*
12* 31*
13* 32 ground TPS sensor.
14 air temperature signal 33*
15* 34 shield wire RPM sensor
16* 35 RPM sensor signal
17 stepper motor + 36*
18 stepper motor – 37 injector cylinder rh
* Not connected 19 stepper motor – 38 ignition coil lh.

70
Electronic injection :computer 5AM 2
Connections Engine Computer
1 start relay command pin 85 20 CAN – H (ccm/dashboard)
2* 21*
3* 22 oxygen sensor signal
Connector B
4 protected power-supply from dash board 23*
5* 24 speed sensor signal in
6 secondary relay command pin 86 25*
7 k-line (reprogramming dashboard) 26*
8* 27 “engine kill” in
9* 28 start signal in
10* 29 CAN – L (ccm/dashboard)
11 negative command oxygen sensor 30*
12* 31*
13* 32 power supply oxygen sensor
14* 33 clutch sensor signal
15* 34*
16 K- line (diagnosis) 35 fall down sensor signal
17 power-supply main relay 36*
18* 37*
* Not connected 19* 38 lateral stand sensor signal.

71
COMPONENTS –IGNITION
The system used is of the inductive type.
The computer works with following parameters:
- Engine load,
- Engine temperature,
- Injection time: determines the command of ignition advance

Primary: to measure
between pin 1and 15.
value:
0,9 a 1,1 Ω

Secondary: to
measure at the high
tension exits.
value:
6,5 a 7,2 KΩ

72
COMPONENTS –IGNITION
Spark plug cap and spark plug
Engine equipped with double ignition

Production make
NGK
position 1 PMR8B
position 2 BPR6ES
Cap resistances 5 k Ω

To avoid fast wear of the platinum electrodes

of the internal plug, it is important not to switch
The high tension cables on the bobine

(cable with red marking – external plug)

73
COMPONENTS – ELECTRICS
Speed sensor
Located at front fork:
inductive active type

Connector with 3 pin:

ÎPower-supply 12V
ÎOutgoing signal from pin 24 connector B
Îground
1

Resistance:
With connector disconnected
between pin 2 e 3
from 500 to 600 Ω circa

74
COMPONENTS – ELECTRICS

Engine temperature sensor

This sensor is supplied with 5V has NTC characteristic, sends to the computer a variable
signal in function of the temperature, to manage stochiometric report during engine warm-up

°C KΩ °C KΩ
- 40 100.950 +40 1.600
- 30 53.100 +50 1.080
- 20 29.120 +60 0.750
- 10 16.600 +70 0.530
0 9.700 +80 0.380
+10 5.970 +90 0.280
+20 3.750 +100 0.204
+30 2.420 +110 0.153
+125 0.102

75
COMPONENTS – ELECTRICS

Crankshaft position sensor

RPM and alignment sensor, measures

engine RPM and position of each cylinder
with respect to TDC. A sensor with
connector with tree wires.:

pin positive tension

pin negative tension
pin shield wire
Resistance value 650 to 720 Ω circa

Air Gap:
Measures sensor length with Calliper:
From 0,6 mm to 0,7mm

76
COMPONENTS – ELECTRICS
Idle speed control
The computer in order to increase the amount of by-pass air, with in consequence the increase
of engine rpm at idle, uses a stepper motor.
Its function consists of a displacement of the central axis which by its rotational movement
opens and closes the bypass, thus allowing air to by-pass the throttle valve.
The parameters used to vary the passage, coming from various sensors are:
- Engine RPM
-Coolant temperature
If the engine is warmed-up, the stepper motor operates in CLOSED LOOP to obtain target
speed set by the computer

Impulse Commands

Resistance value:
between 1 and 4 = 50 Ω
between 2 and 3 = 50 Ω

77
COMPONENTS – ELECTRICS
Emission control

To obtain an ideal mixture it is necessary that the amount of intake air for the combustion is in
equal measure to the theoretical amount needed for a complete combustion of the fuel injected
in the intake manifold

- λ > lean mixture a. Rich mixture (lack of air)

b. Lean mixture (too much air)
- λ < rich mixture
- λ = optimal

78
COMPONENTS – ELECTRICS
Lambda Sensor
In contact with exhaust gas, the oxygen sensor generates an electrical signal of which the value
represents the amount of oxygen present in the exhaust gas itself.
Because the censor and needs to reach a temperature of about 350°C to function correctly, in
order to avoid thermal shock at cold engine condition, the computer foresees in sensor heating.
Sensor and heater are integrated in a ceramic element thus obtaining fast heating. In this way
in very short period of time is obtained the control in so-called closed loop ( lambda control)
which stochiometric report

Schematic of sensor
•1 ceramic coating
•2 protection element
•3 sensor body
•4 ceramic support
•5 plane sensor
•6 protection
•7 electric wire 1- exhaust gas
2 – reference air
3 - heater
4 –reference tension

79
COMPONENTS – ELECTRICS

Three-way catalytic converter

This component is used to reduce three principal polluting elements:

- Carbon Monoxide = CO
- Raw hydrocarbons = HC
- Nitrogen oxides = NOX

the internal construction consists of a metallics support in which is deposited a substrate of a

chemical material that under operating temperature initialise a catalytic process, transforming
CO in CO2, HC and NOx in water vapour and N2.

Catalythic material

Exhaust gas exit Exhaust gas entrance

80
COMPONENTS – ELECTROMECHANICS

Relays (under the seat)

A = Secondary injection relay

B = Lights relay
C = Start relay
D = Main injection relay
A B
Battery (under the seat) D C
YTX 20 CH-BS 18A/h
Maintenance Free

81
COMPONENTS – ELECTROMECHANICS

Engine oil pressure sensor

This sensor per default is shorted to ground. With
the engine running the pressure existing in the
lubrication system will interrupt the contact,
signaled by pin 3 of the gray connector in the
dashboard

Neutral sensor
Also this sensor per default is shorted to ground.
Every time the vehicle is shifted into gear the
contact remains open signaling to the computer
via pin 23 of black connector (A)

82
COMPONENTS – ELECTROMECHANICS
Starter motor

The activation of this actuator is realized

by a solenoid commanded by the
computer:
- Key ON
- Security switches line in continuity
- Start switch on

This command remains present in the

computer for 10 seconds; only when 400
engine rpm are achieved the signal is
automatically deactivated.

characteristics:
12V

83
COMPONENTS – ELECTROMECHANICS

Alternator

Fulcrum screw

Belt tensioner
characteristics:
12V nominal
Max load 40A (550W)
Initial load > 1110 rpm
Regulator 14,2 to14,8V
5000 rpm 10A- 25°C
Range Temp. – 30 a 90°

Belt replacement every

50.000 km
84
COMPONENTS – ELECTROMECHANICS

Procedure for the alternator belt tensioning

To set the correct tensioning of the belt it is

necessary to use the specific tool: “belt
tensioner tool”. and torque wrench

•Fix the fulcrum screws of the alternator (M10)

at approximately 10 Nm
•Put tension to the belt according to the value
described in the workshop manual (different
between belt installed for first-time or already
installed at least one time) and lock the
alternator with the locking screws
•Fix the securities bolts and the relative nut
•Fix with the correct torque the fulcrum screws
and the locking screws

85
Security systems
The security system exists of the following components:
• Fall sensor
• Clutch sensor
• Neutral sensor
• Stand sensor

All of these sensors are directly connected to the computer which in function of
the signals received from these components allow the functioning of the engine
and its start-up

Fall sensor
This sensor correctly positioned and with the engine running is in open contact. In
case the vehicle falls over, the sensor closes its contact to ground via pin 35 of
connector B.
The computer sensing this dangerous situation stalls the engine
If the vehicle is turned upright again, one needs to wait 10 seconds after turning
key to off before turning back to on to allow starting, (activating the power latch)

86
Security systems
LOGIC LATERAL STAND/CLUTCH FOR BREVA 1100 01.03.04

GEAR STAND CLUTCH IGNITION

ENGINE STARTING STAND WARN.LIGHT
ENGAGED
UP OFF
DISENGAGED
NEUTRAL
ENGAGED POSSIBLE
DOWN FUNCTIONS ON
DISENGAGED
ENGAGED
UP OFF
DISENGAGED
GEAR
ENGAGED DOES NOT NOT POSSIBLE
DOWN ON
DISENGAGED FUNCTION

GEAR: Neutral position means contact closed. In gear means contact opened
STAND: Raised means contact closed, lowered means contact open
CLUTCH : Engaged means contact closed, disengaged contact open

87
ENGINE DIAGNOSIS

Diagnostic connector

Besides the possibility to effectuate

the diagnosis of the engine ECU via
the dashboard in position
“diagnostics” faults ACT, the
diagnostic connector is available
under the seat next to the fuse box.
This connection allows to control
with Axone in section parameters
eventual reprogramming of the
computer (currently not foreseen) and
activate some components of the
injection system, visualise faults both
ACT and MEM

88
AXONE

89
AXONE

Software Axone:
The new software 5.0.4 for Axone will permit the connection to the ECU
Select AUTODIAGNOSI, BREVA, 1100, and confirm following the Axone instruction
showed on the screen.

90
AXONE
Throttle valve zero position learning procedure

Is performed in following circumstances:

• Throttle valve body and or sensor replacement,
• Computer replacement or cylinder balancing

Select in the screen ADJUSTING PARAMETERS

The parameter LEARNING THROTTLE POSITION SENSOR

• How do we verify correct implementation? In the screen parameters engine

I should see : throttle position 4,7±0,2 °

91
AXONE

Recovery function

In case any of the following sensor signals is disturbed the computer continues
operation with replacement values.
Dashboard and Axone in any case are showing the malfunction.
Air temperature: 25 °C
Engine temperature: 30 °C , with linear increase parallel to air temp.
Barometric pressure: 1010 hPa
Throttle position sensor: 2,9 ° at minimum, otherwise variable
Stepper motor: Fixed value

92
AXONE

Sonda Lambda:

To verify if the computer uses the lambda sensor feedback signal can be seen in
Screen Components status

The parameter STATUS LAMBDA: should indicate CLOSED.

This condition can be verified at idle, only when all following conditions are met :
Air temperature above 18 °C
Engine temperature above 18 °C
Engine has operated for approximately 2-3 minutes

93
AXONE: active screens

ISO screen:

• MAP Visualise actual mapping present in computer

Engine parameter screen:

Visualise the usual engine parameters. New are the parameters for the stepper
motor
• STEPPER C.L. indicates the step number set by the computer
• EQUIVALENCE OF STEPPER if not at idle, indicates air contribution by the
stepper motor in degrees of throttle opening

94
AXONE: active screens

Component status screen:

It is possible to visualise the component status for the security components
and other systems, like the lambda sensor and rpm sensor

• FALL SENSOR: If vehicle is fallen over it shows TIP OVER

• SWITCH RUN/STOP: I can see in which status the switch is

• IGNITION: indicates if the computer based on the status of the security

components and immobiliser will allow for engine starting

95
AXONE: active screens

Screen component activation:

• From this screen I can activate a series of components

• The CANCEL ERRORS will only delete errors from the engine computer memory

Screen error visualisation:

For the majority of detected errors, once selected the error and pressing the
enter button on Axone, one will see a detailed description of the error.

96
THROTTLE BALANCING
Procedure of adjustment and controlling throttle bodies
Connect Axone to the diagnostic connector of the vehicle and to its battery and follow
the indications given by Axone

ÎConnect the vacuum meter to the two intake collectors

ÎConnect Axone and follow indications
ÎPut the key to ON
ÎMake sure there are no faults present in the computer. In case there are, resolve
them and restart the procedure

97
THROTTLE ALIGNMENT
Î Assure that the LH throttle is resting at the stopper

Note:
Don’t move absolutely the throttle stopper, to avoid the need of throttle body
replacement.

Throttle
stopper

Ä Select the parameter “Self learning of the throttle” in the screen Regulating Parameters
Ä Turn the key to OFF for 30s
Ä Turn the key to ON to reestablish the connection with Axone
Ä Check that the value indicated “Throttle” is 4,5 – 4,9 °. In case the value is not correct replace
the engine computer and repeat the procedure from the beginning.

98
THROTTLE ALIGNMENT
Î Completely close the by-pass screws
Î Start the engine and warm up to 60°
Run the engine at 2000/3000 rpm and with the vacuum meter, check if there is a correct
difference of vacuum between the two cylinders of maximum 1 cm Hg (1,33 kPa).
If this is the case continue at point 1
If difference is higher proceed at point 2

1. Run the engine at idle and check that the vacuum between the two cylinders is balanced.
If this is not the case open ONLY the bypass screw of the cylinder with the highest
underpressure to obtain equal values between left and right

Bypass LH

Bypass RH

99
ALLINEAMENTO FARFALLE

2. Adjust the adjuster on the throttle

bodies connecting rod to reduce the
vacuum difference between left and
right.

Î Apply again the procedure for “Autolearning throttle position”

as explained before

Î Run the engine at idle and check the vacuum difference between left and right.
If difference exists open ONLY the by-pass screw on the side with the higher
underpressure to obtain correct balance.

100
SPECIAL TOOLS: new

codice nome attrezzo note

1 05,94,86,30 belt tensioner tool
oil return ring protection cone
front cover insertion cone
2 05,91,17,30 on cover
4 teeth, d.38 mm. Also usable
3 05,91,26,30 dismantling clutch tool for damper adjustment: equal
to RSV 1000 code 8140191
4 05,91,25,30 gearbox opener
allows removal with filter
internal sparkplug spanner
5 05,90,19,30 installed
6 05,92,80,30 piston ring compressor d.interno cilidnro=92 mm
7 05,92,72,30 distribution cover washer punzone

101
SPECIAL TOOLS: existing
codice nome attrezzo note
verificare se va bene questo
Attrezzino rimozione anelli forcella
8 30949700 del V11
va bene quello dell'RSV 1000
ghiera sterzo
9 D.48 mm codice 8140190
Chiave per smontaggio coperchietto sulla coppa
attrezzo effettuato per V11
10 01 92 91 00 e filtro
11 14 92 96 00 Supporto per scatola cambio attrezzo effettuato per V11
Disco graduato per controllo messa in fase
attrezzo effettuato per V11
12 19 92 96 00 distribuzione e accensione
Freccia per controllo messa in fase distribuzione
attrezzo effettuato per V11
13 17 94 75 60 e accensione
14 12 91 36 00 Attrezzo per smontaggio flangia lato volano attrezzo effettuato per V11
Attrezzo per bloccare il volano e la corona
attrezzo effettuato per V11
15 12 91 18 01 avviamento
16 10 90 72 00 Attrezzo per smontaggio e montaggio valvole attrezzo effettuato per V11
17 30 91 28 10 Attrezzo per bloccaggio corpo intero frizione attrezzo effettuato per V11
18 30 90 65 10 Attrezzo per montaggio frizione attrezzo effettuato per V11
Attrezzo per montare l'anello di tenuta sulla
attrezzo effettuato per V11
19 14 92 71 00 flangia lato volano
Attrezzo per montaggio flangia lato volano
attrezzo effettuato per V11
20 12 91 20 00 completa di anello di tenuta sull'albero motore
Attrezzo montaggio anello di tenuta sulla flangia
attrezzo effettuato per V11
21 19 92 71 00 lato volano
Attrezzo per tenuta ingranaggio albero a camme attrezzo effettuato per V11
22 14 92 73 00
23 65 92 84 00 Mozzo per disco graduato attrezzo effettuato per V11

102
EWD : DASHBOARD
12 TRIP 1
13
TRIP 2
MODE
dashboard
cruscotto
SET
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 171819 20 21 22 23 24 25 26 27 28 293031 32 33 34 3536 37 38 39 40

15
11 LH
14

K 17
16
18
10
19

87 avv . 20
86
8 9
7 21
85
30

pin 11 of
daccmccm
22
PIN
connettore B
connector B 23
pin
pin87
87daof relè
principale 15/54 30
main relay pin
Pin28
28 da ccm
of ccm
A 15 15
A A
28 30 30
A A
connettore
connector BB
pin 27 da ccm
Pin 27 of ccm
connettore B
6 connector B
BATTERY
BATTERIA pin87 da relè
principale
pin 87 of
5 1
BATTERY
BATTERIA Main relay

4 3 2 27 26 24
Legenda:
25
1)1)Front indicatordiRH
Indicatore direzione 8)Oil pressuredx
anteriore warning light 15) Immobilizer
8) Bulbo pressione olio antenna15) 22) Stopimmobilaizer
Antenna switch RH 22) Interruttore stop dx
2)2)Front positionposizione
Lampada light 9)Fuel level sensor
anteriore 9) Sensore 16) Diagnostic
livello connector
benzina 16) 23) Ambient
Presa diagnosi air temperature 23) NTC ambiente (atmosferica)
3)3)Beam
Lampadaheadlight
anabbagliante 10)Light relay 17) Heated handle RH 17)
10) Relè luci 24) Rear indicator
Manopola riscaldata RH dx 24) Indicatore di direzione posteriore dx
4)4)Headlight
Lampada abbagliante 11)Horn 11) Claxon 18) Heated handle LH 18) 25) Stop light
Manopola riscaldata sx 25) Luce stop
5)5)Front indicatordiLHdirezione 12)Light
Indicatore switches
anteriore sx LH 12) Devio luci 19) Handle
sx heater switch
19) 26) Rear indicator
Interruttore LH
riscaldamento manopole 26) Indicatore di direzione posteriore sx
6)6)Alternator
Alternatore 13)Light switches RH 13) Devio luci20) Hazard
dx switch 20) 27) LicenseHazard
Interruttore plate illumination 27) Luce targa
7)7)Starter relay
Relè avviamento 14)CAN line 21) Stop switch LH
14) Linea CAN 21) 28) Ignition stop
Interruttore switchsx 28) Commutatore a chiave

103
EWD : ALTERNATOR
Wiring diagram alternator

B IG SW

IG IG
Statore Ponte
Bridge di
of
Graetz
no lamp

P
L L

Rotore
Batteria
y

carico presente
Load present in ( I )
in (I)
sull’impianto elettrico
to electrical system

104
EWD: SECURITY SYSTEM
BREVA 1100 Security
Logica dilogic
sicurezza
N

B/V Dashboard
Cruscotto N
nero
Black grigio
Gray 25 S M

1 3
R 31
A/G

32
Ro/GM
A/G
5 3 R/N Ar/V
R/B 87 34
87
30 15/54 86
86 D 29 85
85 B/V
R/N 30
30
B Ar 2
Ro/M
R/N M/Vi
G/R
50
Ro/G
AZ/AR

1 17 27 28 33 35 38 23
ECU
B A
Legenda
2 Clutch switch 31 Oil pressure warning
23 Starter
Interruttore
relay
frizione 32 Neutral Gear31 Bulbo pressione olio
switch in
35 LightRelais di avviamento34 Lateral stand32
switch RH sensor
Interruttore cambio in folle
5 Devio luci dx 34 Sensore stampella laterale
29 Main injection relay 50 Tip-over sensor
29 Relais principale di iniezione 50 Sensore di caduta
25 Starter motor
25 Motorino avviamento

105
EWD: ENGINE ECU
8 9
Impianto elettrico
electronic injection
gestione: iniezione
A
1

15
15

1
accensione.
and ignition system
38 28 19 10 Marelli 5AM 2
37 9
27 18
36
35
26 17
8
10
Moto Guzzi Breva
7
7
34
25 16
6 1100
24 15 13
33 5
23 14
6 32 4
22 13
31 3
21 12
30 2
11
29 20 11 1
5 12
L H Legenda:

L 29 14 1)1)Pompa
Fuel pumpbenzina
4
1
11 H 20 2)2)Relè
Secundary injection
secondario relay
iniezione
2 30 3)3)Relè
Mainprincipale
relay
12 21 31 15 4)4)Potenziometro
TPS acceleratore
3
13 22 32 5)5)Sensore
RPM/Phase rpm/fase
sensor
4 6)6)Iniettore
Injector RHcilindro dx
Cylinder
25 14
K 5 23 33 7)7)Iniettore cilindro sx
Injector LH cylinder
6 15 24 34 8)8)Bobina cilindro sx
K 16 IgnitionCoil LH cylinder
7 16 25 35 9)9)Bobina
Ignition cilindro dx
Coil RH cylinder
3 17 26 36 10)
10)Motorino passo/passo
Stepper motor
8 17
18 27
11)
11)Sensore cambio
Neutral Gear N
sensor
9 37 12 Cruscotto con spia EFI
19 12) dash w/ EFI warning light
28 18 13)
13)Sensore press. atmosferica
10 38
Atmospheric air pressure
14) Sensore NTC
14) Air temp sensor
aria
K 19
15) Sensore NTC motore
15) Engine temp sensor
87
87 B 16) Sensore caduta
16)Sensore
17) Tip-over sensor
frizione
85
86
15/54 30 17) Clutch sensor
18) Sensore cavalletto
24 20 18) Stand sensor
30 19) Presa diagnosi
19)Sonda
20) Diagnostic connector
ossigeno
2 1 20)Segnale
21) Oxygene di sensor
velocità veicolo
21)Relè
22) Vehicle speed sensor
avviamento
0
21
23)
22)Pulsante avviamento
Starter Relay
M 24)
23)Interruttore
Starter switch arresto motore
25)
24)Presa
Enginelinea K-ECU/cruscotto
kill switch
22
25) Connector K-line ECU/dash
1 23 L = CAN bassa tensione
HL=
= CAN
CANlowaltatension
tensione
Solenoide motorino avviamento
Starter solenoid pin 50 KH=
= unidirezionale
CAN high tension diagnostica
K= One way diagnosis

106