MOTO GUZZI V7 II ABS Service Station Manual
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MOTO GUZZI V7 II ABS Service Station Manual

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SERVICE STATION MANUAL
2Q000105
V7 II ABS

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Summary of Contents for MOTO GUZZI V7 II ABS

  • Page 1 SERVICE STATION MANUAL 2Q000105 V7 II ABS...
  • Page 2 The reliability of the vehicle also depends on its mechanical conditions. Checking the vehicle before riding it, its regular maintenance and the use of original Moto Guzzi spare parts only are essential factors! For information on the nearest Official Dealer and/or Service Centre consult our website: www.motoguzzi.com...
  • Page 3 This manual provides the main information to carry out regular maintenance operations on your vehicle. This manual is intended to Moto Guzzi Dealers and their qualified mechanics; several concepts have been deliberately omitted as they are considered unnecessary. As it is not possible to include complete mechanical notions in this manual, users should have basic mechanical knowledge or minimum knowledge about the procedures involved when repairing scooters.
  • Page 5 INDEX OF TOPICS CHAR HARACTERISTICS S-TOOLS PECIAL TOOLS MAIN AINTENANCE ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE P SUPP OWER SUPPLY SUSP USPENSIONS CHAS HASSIS BRAK SYS RAKING SYSTEM BODYW ODYWORK PRE DE DELIVERY...
  • Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 7: Safety Rules

    V7 II ABS Characteristics Rules Safety rules Carbon monoxide If you need to keep the engine running while working on the vehicle, please ensure that you do so in an open or very well ventilated area. Never run the engine in an enclosed area. If you do work in an enclosed area, make sure to use a fume extraction system.
  • Page 8 V7 II ABS Characteristics Brake and clutch fluid BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAINTED SURFACES. WHEN SERVICING THE BRAKING SYSTEM OR THE CLUTCH SYSTEM, PROTECT THESE COM- PONENTS WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THESE SYSTEMS.
  • Page 9 CAUTION BEARINGS MUST BE ABLE TO ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE: OTH- ERWISE, THEY NEED TO BE REPLACED. • Only use ORIGINAL Moto Guzzi SPARE PARTS. • Comply with lubricant and consumables use guidelines. • Lubricate parts (whenever possible) before reassembling them.

  • Page 10: Vehicle Identification

    That is to permit the adequate adjustment of the pad friction material to the brake discs. AFTER THE SPECIFIED MILEAGE, TAKE THE VEHICLE TO AN OFFICIAL Moto Guzzi DEALER FOR THE CHECKS INDICATED IN THE "AFTER RUN-IN" TABLE IN THE SCHEDULED MAINTE- NANCE SECTION TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHI- CLE.
  • Page 11 V7 II ABS Characteristics This number consists of numbers and letters, as in the example shown below. ZGULW10015MXXXXXX KEY: ZGU: WMI (World manufacturer identifier) code; LW: model; 1/00 (V7 Stone), 2/00 (V7 Special), 3/00 (V7 Rac- er), 6/00 (V7 Stornello) : versions;...

  • Page 12: Specifications

    V7 II ABS Characteristics Engine ENGINE Specification Desc./Quantity Type traverse-mounted twin-cylinder four-stroke V 90° Cylinder number Engine capacity 744 cm³ (45.40 cu.in) Bore / stroke 80x74 mm (3.15x2.91 in) Compression ratio - V7 Special / V7 Stone / V7 Racer 10.4 : 1...

  • Page 13: Spark Plugs

    V7 II ABS Characteristics Specification Desc./Quantity Fuses 5 (2) - 15 (3) - 20 - 30 A Permanent magnet alternator 12V - 270W SPARK PLUGS Specification Desc./Quantity Standard NGK CPR8EB-9 Spark plug electrode gap 0.6 - 0.7 mm (0.024 - 0.027 in)

  • Page 14: Wheels And Tyres

    V7 II ABS Characteristics Brakes BRAKES Specification Desc./Quantity Front stainless steel floating disc, Ø 320 mm (12.59 in), callipers with 4 different and counteracting plungers Rear 260 mm (10.24 in) stainless steel disc, floating calliper with two 22 mm (0.87 in) diameter pistons...

  • Page 15: Tightening Torques

    V7 II ABS Characteristics Supply FUEL SYSTEM Specification Desc./Quantity Type Electronic injection (Marelli MIU G3) Diffuser Ø 38 mm (1.50 in) Fuel Premium unleaded petrol, minimum octane rating of 95 (NORM) and 85 (NOMM) Tightening Torques Chassis CHAR - 15...

  • Page 16: Front Side Overview

    V7 II ABS Characteristics Front side RONT SUSPENSION TEERING pos. Description Type Quantity Torque Notes Stanchion cap 1 + 1 50 Nm (36.88 lb ft) Calliper bracket fixing screws M6x30 10 Nm (7.38 lb ft) Screws fixing fork stanchions to upper and low-...
  • Page 17 V7 II ABS Characteristics pos. Description Type Quantity Torque Notes Headstock fixing nut M23x1 50 Nm (36.88 lb ft) Handlebar U-bolt fastener screws M8x30 2 + 2 25 Nm (18.44 lb ft) Screws fixing handlebar support U-bolts to M10x60 50 Nm (36.88 lb ft)
  • Page 18 V7 II ABS Characteristics ANDLEBAR AND ONTROLS pos. Description Type Quantity Torque Notes Switch fastener screw SWP 5 1.5 Nm (1.11 lb ft) Counterweight fixing screw 10 Nm (7.38 lb ft) Loctite 243 Screw fastening the clutch control U-bolt to 10 Nm (7.38 lb ft)
  • Page 19 V7 II ABS Characteristics RONT BRAKE SYSTEM pos. Description Type Quantity Torque Notes Brake pump U-Bolt fixing screw 10 Nm (7.38 lb ft) Front brake calliper fixing screw M10x30 50 Nm (36.88 lb ft) Fixing screw for brake fluid pipe on pump and 25 Nm (18.44 lb ft)
  • Page 20 V7 II ABS Characteristics RONT LIGHTS pos. Description Type Quantity Torque Notes Headlamp fixing screw M8x30 15 Nm (11.06 lb ft) Front turn indicator fixing screws 2 + 2 5 Nm (3.69 lb ft) Horn fixing screw M6x16 1 + 1 8 Nm (5.90 lb ft)
  • Page 21 V7 II ABS Characteristics RONT WHEEL pos. Description Type Quantity Torque Notes Front wheel axle M18x1.5 80 Nm (59.00 lb ft) Front brake disc fixing screw M8x20 25 Nm (18.44 lb ft) Loctite 243 ABS-sensor fixing stud bolt 6 Nm (4.43 lb ft)
  • Page 22 V7 II ABS Characteristics HASSIS pos. Description Type Quantity Torque Notes Screw fixing tank mounting rubber M8x14 25 Nm (18.44 lb ft) blocks to frame Cradle front fixing screw M10x30 50 Nm (36.88 lb ft) Screw fastening gearbox to frame M10x55 50 Nm (36.88 lb ft)
  • Page 23 V7 II ABS Characteristics RAME CRADLES pos. Description Type Quantity Torque Notes Screw fixing stand beam to cradle 50 Nm (36.88 lb ft) Screw fastening cradle to frame 50 Nm (36.88 lb ft) Pin fixing engine/gearbox to chassis 50 Nm (36.88 lb ft)
  • Page 24 V7 II ABS Characteristics RIVER FOOTRESTS pos. Description Type Quantity Torque Notes Pedal rubber fastening screw M6x12 10 Nm (7.38 lb ft) Screw fastening rider footrest mounting to 25 Nm (18.44 lb ft) Loct. 243 frame Lever peg fixing 10 Nm (7.38 lb ft) Loct.
  • Page 25 V7 II ABS Characteristics ONTROL pos. Description Type Quantity Torque Notes Gearbox control rod fixing nut 10 Nm (7.38 lb ft) Preselector lever fixing screw M6x20 10 Nm (7.38 lb ft) Gearbox transmission lever fixing M6x20 10 Nm (7.38 lb ft)
  • Page 26 V7 II ABS Characteristics EAR BRAKE LEVER pos. Description Type Quantity Torque Notes Nut fixing rear brake lever 20 Nm (14.75 lb ft) Rear brake fluid reservoir fixing M5x15 3 Nm (2.21 lb ft) screw Rear brake rod fixing lock nut...
  • Page 27 V7 II ABS Characteristics IDER FOOTREST EAR BRAKE LEVER pos. Description Type Quantity Torque Notes Screw fastening right hand rider foot- M8x20 20 Nm (14.75 lb ft) Loctite 243 rest mounting plate to cradle Rear brake lever fixing screw M6x20 10 Nm (7.38 lb ft)
  • Page 28 V7 II ABS Characteristics UEL TANK pos. Description Type Quantity Torque Notes Rear tank fixing screw 25 Nm (18.44 lb ft) Screw fastening cap flange to tank 3 Nm (2.21 lb ft) CHAR - 28...
  • Page 29 V7 II ABS Characteristics UEL SUPPLY SYSTEM pos. Description Type Quantity Torque Notes Fuel pump support fixing screw to the M5x16 5 Nm (3.69 lb ft) tank Screws fixing sleeve to cylinder head 2 + 2 10 Nm (7.38 lb ft) Screw/washer fixing on sleeve 8 Nm (5.90 lb ft)
  • Page 30 V7 II ABS Characteristics ILTER BOX pos. Description Type Quantity Torque Notes Air filter box fastening screw SWP 5x20 3 Nm (2.21 lb ft) Air filter box cover fastening screw SWP 5x14 3 Nm (2.21 lb ft) ODYWORK CENTRAL SECTION ADDLE pos.
  • Page 31 V7 II ABS Characteristics ODYWORK CENTRAL SECTION ADDLE pos. Description Type Quantity Torque Notes Saddle release block fixing screw M6x25 10 Nm (7.38 lb ft) Throttle body cover fastener screw M5x14 4 Nm (2.95 lb ft) Side fairing fixing screw M5x9 4 Nm (2.95 lb ft)
  • Page 32 V7 II ABS Characteristics pos. Description Type Quantity Torque Notes Side fairing fixing screw 2 + 2 8 Nm (5.90 lb ft) Side fairing fixing screw 1 + 1 5 Nm (3.69 lb ft) Screw fixing oval plate to side fairing 2 + 2 5 Nm (3.69 lb ft)
  • Page 33 V7 II ABS Characteristics XHAUST SYSTEM pos. Description Type Quantity Torque Notes Exhaust pipe fixing nut to the engine 10 Nm (7.38 lb ft) Exhaust pipe fixing clamp screw to 10 Nm (7.38 lb ft) the compensator Compensator fixing clamp screw to 10 Nm (7.38 lb ft)
  • Page 34 V7 II ABS Characteristics XHAUST SYSTEM pos. Description Type Quantity Torque Notes Screw fixing central manifold to 10 Nm (7.38 lb ft) bracket (Stornello) Lambda probe fastener M18x1.5 1 + 1 38 Nm (28.03 lb ft) Heat shield fixing screw 2 + 2 8 Nm (5.90 lb ft)
  • Page 35 V7 II ABS Characteristics SYSTEM pos. Description Type Quantity Torque Notes Screw fixing ABS control unit support 10 Nm (7.38 lb ft) to chassis Back side EAR TRANSMISSION SWINGARM pos. Description Type Quantity Torque Notes Swingarm clamp retaining screw M10x45 30 Nm (22.13 lb ft)
  • Page 36 V7 II ABS Characteristics EAR SUSPENSION pos. Description Type Quantity Torque Notes Upper screw fastening shock absorber to M6x35 10 Nm (7.38 lb ft) Loctite 243 frame Lower pin fastening left shock absorber to M10x1.5 35 Nm (25.81 lb ft)
  • Page 37 V7 II ABS Characteristics ASSENGER FOOTRESTS pos. Description Type Quantity Torque Notes Pedal rubber fastening screw M6x12 10 Nm (7.38 lb ft) Screw fastening passenger footrest mounting 25 Nm (18.44 lb ft) Loct. 243 to frame CHAR - 37...
  • Page 38 V7 II ABS Characteristics EAR WHEEL pos. Description Type Quantity Torque Notes Rear wheel axle nut up to frame se- M16x1.5 120 Nm (88.51 lb ft) rial number ZGULWS00XEM200368 Rear wheel axle nut up to frame se- M16x1.5 100 Nm (73.76 lb ft)
  • Page 39 V7 II ABS Characteristics EAR LIGHTS pos. Description Type Quantity Torque Notes Screw fastening taillight support to M5x14 4 Nm (2.95 lb ft) mudguard Rear turn indicator fixing screw 5 Nm (3.69 lb ft) CHAR - 39...
  • Page 40 V7 II ABS Characteristics EAR SECTION BODYWORK ICENSE PLATE MOUNTING pos. Description Type Quantity Torque Notes Retroreflector support fixing screw to the license M5x10 4 Nm (2.95 lb ft) plate Retroreflector fixing nut retainer to the support 4 Nm (2.95 lb ft)
  • Page 41 V7 II ABS Characteristics EAR MUDGUARD pos. Description Type Quantity Torque Notes Rear mudguard front and central fixing screw 10 Nm (7.38 lb ft) (Special/Stone/Racer) Screw fixing rear mudguard bracket to chassis 10 Nm (7.38 lb ft) (Stornello) Rear mudguard side fixing screw (Special/ M8x30 20 Nm (14.75 lb ft)
  • Page 42 V7 II ABS Characteristics LECTRICAL SYSTEM pos. Description Type Quantity Torque Notes Fuse box bracket fixing screw M5x12 4 Nm (2.95 lb ft) Battery holder bracket fastening screw Manual Recommended products chart Piaggio & C. S.p.A. prescribes eni products for...
  • Page 43 V7 II ABS Characteristics Product Description Specifications AGIP BRAKE 4 Brake fluid SAE J 1703 -FMVSS 116 - DOT 3/4 - ISO 4925 - CUNA NC 956 DOT 4 synthetic fluid NOTE USE ONLY NEW BRAKE FLUID. DO NOT MIX DIFFERENT BRANDS OR TYPES OF OIL WITHOUT CHECKING THEIR BASE COMPATIBILITY.
  • Page 44 INDEX OF TOPICS S-TOOLS PECIAL TOOLS...

  • Page 45: Special Tools

    V7 II ABS Special tools SPECIAL TOOLS Stores code Description 19.92.61.00 Punch for seal ring of bevel gear set pin- 19.92.88.00 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...
  • Page 46 V7 II ABS Special tools Stores code Description 19.92.64.00 Punch for external ring of tapered bearing on bevel gear set pinion holding body 19.92.65.00 Punch for external ring of gearcase bear- 19.92.76.00 Extractor for swinging arm holder bearing on gearbox cover...
  • Page 47 INDEX OF TOPICS MAIN AINTENANCE...

  • Page 48: Scheduled Maintenance Table

    V7 II ABS Maintenance Scheduled maintenance table NOTE CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VE- HICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS, OFF ROAD OR FOR TRACK USE. NOTE THE TIMES LISTED ON THE SCHEDULED MAINTENANCE TABLE INCLUDE TIME DEDICATED TO MANAGEMENT ACTIVITIES.

  • Page 49: Transmission Fluid

    V7 II ABS Maintenance km x 1,000 (mi x 1,000) 1 (0.6) 10 (6.2) (12.4) (18.6) (24.9) (31.1) (37.3) Brake pipes Clutch wear Brake pads wear (7) Labour time (minutes) SCHEDULED MAINTENANCE TABLE ONLY FOR THE ASIA/PACIFIC MARKET OUTINE MAINTENANCE TABLE...

  • Page 50: Transmission Fluid

    V7 II ABS Maintenance Check • Keep the vehicle upright with both wheels on the ground. • Unscrew and remove the cap/dipstick (1). • The level is correct if the oil is close to the hole of the cap/dipstick (1).

  • Page 51: Engine Oil

    V7 II ABS Maintenance Engine oil Check CAUTION ENGINE MUST BE WARM TO CHECK ENGINE OIL LEVEL. ENGINE OIL LEVEL MUST BE CHECKED WHEN THE ENGINE IS WARM AND WITH THE DIP- STICK INSERTED BUT NOT SCREWED IN. IF YOU CHECK LEVEL WHEN THE ENGINE IS COLD, OIL LEVEL COULD TEMPORARILY DROP BELOW THE 'MIN' MARK.

  • Page 52: Engine Oil Filter

    V7 II ABS Maintenance Replacement • Place a container with 2000 cm³ (122.05 cu.in) capacity under the drainage plugs (1). • Unscrew and remove the drainage plugs (1). • Unscrew and remove the filler plug (2). • Drain the oil into the container; allow several minutes for oil to drain out com- pletely.

  • Page 53: Gearbox Oil

    V7 II ABS Maintenance Gearbox Oil EARBOX pos. Description Type Quantity Torque Notes Neutral sensor 10 Nm (7.38 lb ft) Plate fixing screw Torx M5x16 4 Nm (2.95 lb ft) Loct. 243 Bearing block washers fixing screw TSEI 10 Nm (7.38 lb ft) Loct.
  • Page 54 V7 II ABS Maintenance LUTCH pos. Description Type Quantity Torque Notes Crown screws M6x16 10 Nm (7.38 lb ft) Loctite 243 Gearbox screws M8x35 25 Nm (18.44 lb ft) Bearing block washers fixing screws TSEI 10 Nm (7.38 lb ft) Loct.

  • Page 55: Air Filter

    V7 II ABS Maintenance DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO THE FLUID. WHEN USING A FUNNEL OR ANY OTHER ELEMENT, MAKE SURE IT IS PERFECTLY CLEAN. Air filter • Remove the saddle • Unhook the connector from the air-box cover •...
  • Page 56 V7 II ABS Maintenance • Remove the sleeve • Remove the battery • Remove the MIU G3 control unit con- nector support bracket fixing screw • Disconnect the MIU G3 control unit connector MAIN - 56...
  • Page 57 V7 II ABS Maintenance • Unscrew 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 •...
  • Page 58 V7 II ABS Maintenance Air filter housing HASSIS pos. Description Type Quantity Torque Notes Screw fixing tank mounting rubber M8x14 25 Nm (18.44 lb ft) blocks to frame Cradle front fixing screw M10x30 50 Nm (36.88 lb ft) Screw fastening gearbox to frame M10x55 50 Nm (36.88 lb ft)
  • Page 59 V7 II ABS Maintenance pos. Description Type Quantity Torque Notes Screw fixing license plate holder arc 2 + 2 25 Nm (18.44 lb ft) to chassis (Stornello) Screw fixing exhaust silencer mount- M8x16 25 Nm (18.44 lb ft) Loctite 243...
  • Page 60 V7 II ABS Maintenance • Move the filter box to the side enough to allow removal of the fixing screws (2) on the left side of the filter box support. • 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.

  • Page 61: Air Filter Housing Installation

    V7 II ABS Maintenance • Disconnect the blow-by pipe • Remove the air-box cover • Remove sliding the complete filter box out toward the rear Air filter housing installation • Insert the filter box from the rear MAIN - 61...
  • Page 62 V7 II ABS Maintenance • Insert the throttle 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 •...

  • Page 63: Checking The Valve Clearance

    V7 II ABS Maintenance • Move the filter box to the side enough to allow 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.
  • Page 64 V7 II ABS Maintenance • Remove the left spark plug cover • Disconnect the spark plug tube • Remove the spark plug • Remove the six head cover fixing screws and collect the washers MAIN - 64...
  • Page 65 V7 II ABS Maintenance • Remove the head cover together with the gasket • Loosen the nut (1) • Use a screwdriver to act on set screw (2) until the following clearances are obtained: Technical specifications Values valid with control clearance between rockers and valve Inlet valve: 0.15 mm (0.0059 in)

  • Page 66: Braking System

    V7 II ABS Maintenance Braking system RONT BRAKE SYSTEM pos. Description Type Quantity Torque Notes Brake pump U-Bolt fixing screw 10 Nm (7.38 lb ft) Front brake calliper fixing screw M10x30 50 Nm (36.88 lb ft) Fixing screw for brake fluid pipe on pump and 25 Nm (18.44 lb ft)
  • Page 67 V7 II ABS Maintenance EAR BRAKE CALLIPER pos. Description Type Quantity Torque Notes Rear brake calliper fixing screw M8x30 25 Nm (18.44 lb ft) Drilled screw for brake pipe on cal- 25 Nm (18.44 lb ft) liper Level check Brake fluid check •...
  • Page 68 CHECK BRAKING EFFICIENCY. IN CASE OF EXCESSIVE TRAVEL OF THE BRAKE LEVER OR POOR PERFORM- ANCE OF THE BRAKING SYSTEM, TAKE YOUR VEHICLE TO AN Official Moto Guzzi Dealer, AS IT MAY BE NECES- SARY TO PURGE THE AIR IN THE SYSTEM. MAIN - 68...
  • Page 69 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 70 V7 II ABS Electrical system LECTRICAL SYSTEM pos. Description Type Quantity Torque Notes Speed sensor fastening screw 10 Nm (7.38 lb ft) Coil retainer nut 2 + 2 10 Nm (7.38 lb ft) Voltage regulator fixing screw 10 Nm (7.38 lb ft) Control unit cable grommet fixing 4 Nm (2.95 lb ft)
  • Page 71 V7 II ABS Electrical system LECTRICAL SYSTEM pos. Description Type Quantity Torque Notes Fuse box bracket fixing screw M5x12 4 Nm (2.95 lb ft) Battery holder bracket fastening screw Manual Components arrangement key: ELE SYS - 71...
  • Page 72 V7 II ABS Electrical system 1. Instrument panel 2. Coil 3. Fuel pump 4. Injector 5. Taillight 6. MIU G3 Control Unit 7. Speed sensor 8. Starter motor 9. Engine speed sensor 10.Fuses 11.Battery 12.Head temperature sensor 13.Instrument panel air sensor 14.Headlamp...
  • Page 73 V7 II ABS Electrical system • 1 shield Small parts and mountings • Large black 290x4.5 clamps • Medium black 190x4.5 clamps • Small black 160x2.5 clamps • Cable guide • Cable grommet (there are various types of cable grommets) •...
  • Page 74 V7 II ABS Electrical system 13.Check Regulator and Flywheel connection. 14.Check whether the right lambda probe is inserted on the cable grommet under the clutch housing. 15.Check right and left Lambda connections. 16.Check the presence of the Pull Up module and the presence of the black hose under the trans- parent one.
  • Page 75 V7 II ABS Electrical system TABLE A 1. Main wiring harness 2. Clamp that secures the main cabling to the headlamp support plate 3. Ambient temperature sensor 4. Clamp that secures the ambient temperature sensor to the front headlamp support plate 5.
  • Page 76 V7 II ABS Electrical system 10. Wiring harness ABS and MGCT warning lights 11. Clamp (V7 RACER) TABLE A1 1. Main wiring harness 2. Clamp that secures the main cabling to the headlamp support plate 3. Ambient temperature sensor 4. Clamp that secures the ambient temperature sensor to the front headlamp support plate 5.
  • Page 77 V7 II ABS Electrical system TABLE 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 (5) can be tightened with a clamp in or- der to avoid them disconnecting.
  • Page 78 V7 II ABS Electrical system 8. Clamps TABLE C 1. Key connector 2. Left turn indicator connector • Both connectors, once connected, are positioned behind the steering tube. TABLE D 1. Main cable harness 2. Gas cables 3. Cable tie that secures the main cabling to the frame in correspondence to the grey taping •...
  • Page 79 V7 II ABS Electrical system TABLE E 1. Left light switch connector 2. Right turn indicator connector 3. Clutch switch connector 4. Right light switch connector 5. Cable tie that secures the cabling in correspond- ence to the grey tapings 6.
  • Page 80 V7 II ABS Electrical system TABLE H 1. Clamp 2. Cable guide TABLE I 1. Cable grommet 2. Speed sensor ELE SYS - 80...
  • Page 81 V7 II ABS Electrical system 3. Speed sensor wiring harness TABLE L 1. ABS connections 2. Clamp Central part TABLE A 1. Oil pressure bulb 2. Engine head temperature sensor 3. Right injector 4. Rear stop switch 5. Gear in neutral switch 6.
  • Page 82 V7 II ABS Electrical system 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 TABLE E 1. Side stand switch connector ELE SYS - 82...
  • Page 83 V7 II ABS Electrical system TABLE F 1. Starter motor actuator connector 2. Side stand cabling 3. Cable grommet TABLE G 1. Positive starter motor cable 2. Cable grommet • Check that the hood which covers the starter motor positive is inserted well and that the nut is secured correctly to the prescribed torque.
  • Page 84 V7 II ABS Electrical system 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 TABLE L 1. Main cable harness 2. Cable tie that secures the main cabling to the...
  • Page 85 V7 II ABS Electrical system TABLE M 1. Left lambda probe 2. Right Lambda probe 3. Clamp • Pass both lambda probe cables behind the intake manifold. • In the internal part of the chassis, in the point indicated in the figure, is a plastic hook for the fixing of the right lambda probe connector.
  • Page 86 V7 II ABS Electrical system • Check the cable which goes from the battery positive to the fuse box to be sure it is covered by the sheath and that the terminal is covered by the heat shrink. 2. Battery negative •...
  • Page 87 V7 II ABS Electrical system TABLE R 1. Engine oil bulb 2. Clamp TABLE 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...
  • Page 88 V7 II ABS Electrical system TABLE V 1. Voltage cable 2. Coil • Indication of 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...
  • Page 89 V7 II ABS Electrical system TABLE X 1. Pick Up connector TABLE Y 1. Left horn 2. Right horn Back side TABLE A 1. Rear speed sensor cabling 2. Cable grommets ELE SYS - 89...
  • Page 90 V7 II ABS Electrical system General wiring diagram key: 1. Multiple connectors 2. Air temperature sensor 3. ABS warning light 4. Instrument panel ELE SYS - 90...
  • Page 91 V7 II ABS Electrical system 5. Light relay 6. Starter motor relay 7. Clutch switch 8. Right hand light switch 9. Horn 10.Left light switch 11.GPS wiring 12.Rear stop switch 13.Front stop switch 14.Ignition switch 15.Rear right turn indicator 16.Stop - position bulb 17.Taillight...
  • Page 92 V7 II ABS Electrical system 43.Front position 44.High/low beam bulb 45.Front right turn indicator 46.ABS control unit 47.Front ABS sensor 48.Rear ABS sensor 49.ABS Fuse 50.MGCT warning light 51.Bluedash pre-installation 52.USB pre-installation Cable colour: Ar orange Az sky blue B blue...
  • Page 93 V7 II ABS Electrical system • This is shown only after each start-up for 5 seconds; afterwards, it will shift to the standard view. To reset Service proceed as follows: • Hold down the key (A). • Turn the ignition key to "ON".
  • Page 94 V7 II ABS Electrical system • Take the measurement; The correct value is determined by subtracting the wire resistance of the tester obtained by touching the two pins. Example: • Resistance of stage 1 read on the display = 0.67 Ohm •...
  • Page 95 V7 II ABS Electrical system • 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"...
  • Page 96 V7 II ABS Electrical system • Start the engine, after about one minute of operating bring the speed to 3000-5000 RPM, then measure with a tester the voltage at the battery poles that must always be between 13V and 15V. Otherwise, if the correct operation of the alternator has already been checked, replace the regulator.
  • Page 97 V7 II ABS Electrical system 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 malfunction is detected with a brake activated and the starter button pressed (voltage of 12V read at PIN 6).

  • Page 98: Control Unit

    V7 II ABS Electrical system Fuses FUSE LOCATION A) Stop lights, tail lights, horn (15 A). B) GPS predisposition, low beam / high beam, passing, USB, bluedash (15 A). C) ECU, engine kill, start relay, instrument panel, injection loads relay (15 A).

  • Page 99: Speed Sensor

    V7 II ABS Electrical system Battery Characteristic Battery 12 V - 12 Ah Speed sensor VEHICLE FRONT SPEED SENSOR FUNCTION:To indicate the vehicle speed by read- ing the front wheel turning speed. OPERATION / OPERATING PRINCIPLE:Magne- toresistive sensor: a square-wave pulse is gener- ated with voltage approx.
  • Page 100 V7 II ABS Electrical system restore them. If there is, PIN 2 of the sensor on the cable harness side, with the sensor disconnected and key set to ON, must have 12V voltage approximately: if there is no voltage, check PIN 2 for continuity with the vehicle ground connection: if it is grounded, restore the cable harness.
  • Page 101 V7 II ABS Electrical system OK, check that the tyre pressure is the correct one. If it is not OK, restore it; if it is OK, replace the speed sensor. VEHICLE REAR SPEED SENSOR FUNCTION:To indicate the vehicle speed by read- ing the rear wheel turning speed.
  • Page 102 V7 II ABS Electrical system Troubleshooting:Check speed sensor retainer. If it is not OK, restore it. If it is OK, check if the tone wheel is dirty, deformed or wrongly fixed. If any of this happens, replace the tone wheel. Otherwise, replace the speed sensor.
  • Page 103 V7 II ABS Electrical system 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 •...
  • Page 104 V7 II ABS Electrical system 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.
  • Page 105 V7 II ABS Electrical system Troubleshooting • An interruption in the sensor circuit has been detected, from PIN 20 to PIN 29 of the control unit connector. • Check the sensor connector and the injection ECU connector: • If the values are incorrect restore them.
  • Page 106 V7 II ABS Electrical system • 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 •...
  • Page 107 V7 II ABS Electrical system • 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.
  • Page 108 V7 II ABS Electrical system ELECTRICAL ERRORS Check the air-fuel ratio / right Lambda probe P0130 - short to positive / open circuit, short to negative or carburetion excessively lean / signal not plausible for abnormal title correction or probe signal fault.
  • Page 109 V7 II ABS Electrical system Error cause Short-circuit to positive: excessive voltage at PIN 2 of the control unit connector. Short-circuit to negative: lack of insulation from ground on the sensor connector PIN 4. Open circuit: circuit interruption. Troubleshooting Short-circuit to positive: •...
  • Page 110 V7 II ABS Electrical system ELECTRICAL ERRORS Check the air-fuel ratio / right Lambda probe P0136 - short to positive / open circuit, short to negative or carburetion excessively lean / signal not plausible for abnormal title correction or probe signal fault.
  • Page 111 V7 II ABS Electrical system • Disconnect the sensor connector and the control unit connector. • Check the sensor connector PIN 1 ground insulation. In the absence of insulation restore the cabling. • Check the sensor connector PIN 2 ground insulation. In the absence of insulation restore the cabling.
  • Page 112 V7 II ABS Electrical system Function In charge of telling the control unit whether the mixture is lean or rich. Operation / Operating principle The Marelli injection control unit reads and inter- prets a voltage generated by the difference in oxy- gen content between the exhaust fumes and the ambient.
  • Page 113 V7 II ABS Electrical system • Verify that there is no short to battery positive on sensor connector PIN 2 (corresponding to control unit connector PIN 12); if there is a short, restore the cabling. Open circuit: • Disconnect the control unit connector and the sensor connector.
  • Page 114 V7 II ABS Electrical system • Check the sensor connector PIN 3 ground insulation. In the absence of insulation restore the cabling. • If PIN 3 is insulated from ground and in the absence of other errors (fuel pump, injector, coil), this means that the control unit is most likely faulty.
  • Page 115 V7 II ABS Electrical system • 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 11); if there is a short, restore the cabling.
  • Page 116 V7 II ABS Electrical system • Disconnect the sensor connector. • Check the sensor connector PIN 3 ground insulation. In the absence of insulation restore the cabling. • If PIN 3 is insulated from ground and in the absence of other errors (fuel pump, injector, coil), this means that the control unit is most likely faulty.
  • Page 117 V7 II ABS Electrical system Shorted to positive: • Disconnect the injector connector, turn the key to ON and activate the component through the diagnostics instrument. • Verify the absence of voltage at the injector connector PIN 2; if present, restore the cabling, otherwise proceed with the following checks.

  • Page 118: Fuel Pump

    V7 II ABS Electrical system Shorted to positive: • Disconnect the injector connector, turn the key to ON and activate the component through the diagnostics instrument. • Verify the absence of voltage at the injector connector PIN 2; if present, restore the cabling, otherwise proceed with the following checks.
  • Page 119 V7 II ABS Electrical system 3. Signal + to instrument panel (orange/violet cable) 4. Ground (blue cable) CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN- NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
  • Page 120 V7 II ABS Electrical system Coil Function It controls the ignition spark plug in order to gen- erate the fuel ignition spark. Operation / Operating principle Inductive discharge system. Level in electrical circuit diagram:Left coil and injector Location: • centred under the fuel tank.
  • Page 121 V7 II ABS Electrical system 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.
  • Page 122 V7 II ABS Electrical system • Disconnect the coil connector, turn the key to ON and activate the component through the diagnostics instrument. • Verify the presence of voltage on the coil connector PIN 3: if present, restore the cabling, otherwise replace the coil.
  • Page 123 V7 II ABS Electrical system Warning light always off Troubleshooting • Check the sensor connector and the instrument panel connector (PIN 11): If not OK, restore. If OK, check the continuity of the purple cable between the sensor connector and the in- strument panel connector PIN 11: if not OK, restore the cable harness;...
  • Page 124 V7 II ABS Electrical system Troubleshooting • Carry out the check procedure on the green black sensor/control unit cable. • Restore if damaged. • If OK, with the transmission in neutral, check for continuity to ground of the sensor connector.
  • Page 125 V7 II ABS Electrical system • Clutch pulled: closed circuit (continui- • Clutch released: open circuit (infinite resistance) Pin-out: 1. 12 V Voltage (brown white cable) 2. Ground (blue black cable) Even with the clutch lever pulled, the vehicle does not start Troubleshooting •...
  • Page 126 V7 II ABS Electrical system Level in electrical circuit diagram:Start-up ena- bling switches Location: • sensor: on side stand supporting plate • connector: left side, near the starter motor Electrical characteristics: • Side Stand Up: closed circuit (continu- ity) •...
  • Page 127 V7 II ABS Electrical system Air temperature sensor - instrument panel Function It tells the ambient air temperature to the instru- ment panel. Operation / Operating principle NTC type sensor (resistance sensor, inversely variable with temperature). Level in electrical circuit diagram:Temperature...
  • Page 128 V7 II ABS Electrical system • 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 • If there is no voltage at PIN 1 replace the instrument panel.
  • Page 129 V7 II ABS Electrical system 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) DIAGNOSIS •...
  • Page 130 V7 II ABS Electrical system 10.Diagnosis line (L) - Communication line 11.Throttle position signal - Analogue input 12.Engine revolution sensor - Frequency input 13.Right injector control - Power output 14.Right coil control - Power output 15.Injection telltale light control - Digital output 16.Fall sensor signal - Digital input...
  • Page 131 V7 II ABS Electrical system 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.Battery ELE SYS - 131...
  • Page 132 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 133 V7 II ABS Engine from vehicle HASSIS pos. Description Type Quantity Torque Notes Screw fixing tank mounting rubber M8x14 25 Nm (18.44 lb ft) blocks to frame Cradle front fixing screw M10x30 50 Nm (36.88 lb ft) Screw fastening gearbox to frame M10x55 50 Nm (36.88 lb ft)
  • Page 134 V7 II ABS Engine from vehicle pos. Description Type Quantity Torque Notes Screw fixing exhaust silencer mount- M8x16 25 Nm (18.44 lb ft) Loctite 243 ing to frame (Special/Stone/Racer) Vehicle preparation • To arrange for the removal of the engine block, you must first remove the saddle, fuel tank, side fairings and the battery •...
  • Page 135 V7 II ABS Engine from vehicle • Remove the muffler NOTE REPEAT THE OPERATION ALSO FOR THE LEFT SILENC- (V7 STORNELLO) • Remove the fixing spring of the silenc- er to the central manifold. • Unscrew and remove the fixing screw of the silencer at the support bracket and recover the nut and the washer.
  • Page 136 V7 II ABS Engine from vehicle • Remove the fixing springs of the cen- tral muffler to the front mufflers. • Undo and remove the screw fixing the central muffler to the support bracket. • Remove the central manifold. •...
  • Page 137 V7 II ABS Engine from vehicle • Remove the ground lead connector • Remove the starter motor fixing screws • Remove the starter motor • Remove the lambda probe, side stand and blow by recovery wiring retainer clamps • Disconnect the connectors of the lambda probes...
  • Page 138 V7 II ABS Engine from vehicle • Disconnect the blow-by recovery pipe after having removed the clip clamp (V7 SPECIAL / V7 STONE / V7 RACER) • Remove the exhaust ring fixing nuts, taking care to recover the washers •...
  • Page 139 V7 II ABS Engine from vehicle • Remove the ring nuts • Loosen the clamps between the joint and the exhaust manifolds • Remove the manifolds (V7 STORNELLO) • Undo and remove the fixing nuts of the exhaust ring and recover the washers.
  • Page 140 V7 II ABS Engine from vehicle • Remove the ring nut and the spacers. • Remove the right front manifold. • Repeat the procedure for the left front manifold. • Remove the spark plug covers • Disconnect the caps from the spark...
  • Page 141 V7 II ABS Engine from vehicle • Disconnect the blow-by oil recovery tubes from the big ends • Remove the fixing screws of the injectors and disconnect them • Disconnect the engine temperature sensor connector • Loosen the retainer clamps of the sleeve, from the intake pipe...
  • Page 142 V7 II ABS Engine from vehicle • Disconnect the clutch cable from the lever • Disconnect the clutch cable from the disengagement lever • Remove the fixing screws of the right footrest support • Remove the lower fixing pin of the cra-...
  • Page 143 V7 II ABS Engine from vehicle • Remove the front screws fixing the cra- dle, making sure to recover the nuts and washers • Remove the two rear screws that fix the cradle • Disconnect the side stand switch con- nector •...
  • Page 144 V7 II ABS Engine from vehicle • Slightly lower the engine to allow the removal of the pre-selector lever • Remove the cradle together with the side stand and gear footrest • Remove the cable grommet and dis- connect the cable harness from the rear brake pipe •...
  • Page 145 V7 II ABS Engine from vehicle • Remove the cable grommet and disconnect the cable harness from the rear brake • After removing the clamp, disconnect the ABS sensor and rear stop • Remove the fixing screw of the rear brake tank •...
  • Page 146 INDEX OF TOPICS NGINE...
  • Page 147 V7 II ABS Engine TO CONSULT THE CHAPTER ABOUT THE ENGINE AND ITS COMPONENTS PLEASE REFER TO THE APPROPRIATE MANUAL: "MSS Engine V750 IE My2012" ENG - 147...
  • Page 148 INDEX OF TOPICS P SUPP OWER SUPPLY...
  • Page 149 V7 II ABS Power supply Circuit diagram key: 1. Fuel tank 2. Throttle body 3. Fuel filter 4. Fuel delivery pipe 5. Fuel pump unit Injection P SUPP - 149...
  • Page 150 V7 II ABS Power supply Diagram key: 1. Control unit position 2. Ignition switch 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...
  • Page 151 V7 II ABS Power supply 13.Side stand ECU INFO screen page This screen page shows general data regarding the control unit, for example software type, map- ping, control unit programming date INFO ECU SCREEN PAGE Specification Desc./Quantity Mapping PARAMETERS screen page...
  • Page 152 V7 II ABS Power supply Navigator characteristic P.A.D.S. characteristic Description / Value Left lambda probe voltage Lambda probe voltage 1 100 - 900 mV (indicative values) Signal when energized that the control unit receives from the lambda probe: inversely pro-...
  • Page 153 V7 II ABS Power supply Navigator characteristic P.A.D.S. characteristic Description / Value Idle motor Stepper Left lambda probe heater Lambda probe heater 1 Right lambda probe heater Lambda probe heater 2 Headlamp relay Headlamp relay Fuel pump relay Fuel pump relay...
  • Page 154 V7 II ABS Power supply Navigator P.A.D.S. Navigator Description / Value P.A.D.S Description / Value characteristic characteristic Power-Latch in course / Power-Latch finished / Engine in stop phase Engine control Synchronized on the 4 stroke cycle / Not synchronized on the 4 stroke cy-...
  • Page 155 V7 II ABS Power supply ERRORS screen page This screen page displays any errors detected in the vehicle (ATT) or stored in the control unit (MEM) and you can check that the cancellation of error (STO) has taken place. ERRORS DISPLAY Navigator P.A.D.S.
  • Page 156 V7 II ABS Power supply Navigator P.A.D.S. Navigator Description / Value P.A.D.S Description / Value characteristic characteristic Left cylinder in- Injector circuit short circuit to positive/ short circuit to Short circuit to positive / Short circuit to jector cylinder 1...
  • Page 157 V7 II ABS Power supply ADJUSTABLE PARAMETERS Navigator characteristic P.A.D.S. characteristic Description / Value Throttle position self-acquisi- TPS reset tion Saved data file download Mem. data download (Down- load + Clearing) Clearing memorized data Mem. data download (Down- load + Clearing)
  • Page 158 INDEX OF TOPICS SUSP USPENSIONS...
  • Page 159 V7 II ABS Suspensions Front RONT WHEEL pos. Description Type Quantity Torque Notes Front wheel axle M18x1.5 80 Nm (59.00 lb ft) Front brake disc fixing screw M8x20 25 Nm (18.44 lb ft) Loctite 243 ABS-sensor fixing stud bolt 6 Nm (4.43 lb ft)
  • Page 160 V7 II ABS Suspensions Handlebar ANDLEBAR AND ONTROLS pos. Description Type Quantity Torque Notes Switch fastener screw SWP 5 1.5 Nm (1.11 lb ft) Counterweight fixing screw 10 Nm (7.38 lb ft) Loctite 243 Screw fastening the clutch control U-bolt to 10 Nm (7.38 lb ft)
  • Page 161 V7 II ABS Suspensions ANDLEBAR AND ONTROLS pos. Description Type Quantity Torque Notes Switch fastener screw SWP 5 1.5 Nm (1.11 lb ft) Semi-handlebar fixing screw M6x25 10 Nm (7.38 lb ft) Counterweight fixing screw 10 Nm (7.38 lb ft)

  • Page 162: Front Fork

    V7 II ABS Suspensions Front fork RONT SUSPENSION TEERING pos. Description Type Quantity Torque Notes Stanchion cap 1 + 1 50 Nm (36.88 lb ft) Calliper bracket fixing screws M6x30 10 Nm (7.38 lb ft) Screws fixing fork stanchions to upper and low-...
  • Page 163 V7 II ABS Suspensions pos. Description Type Quantity Torque Notes Headstock fixing nut M23x1 50 Nm (36.88 lb ft) Handlebar U-bolt fastener screws M8x30 2 + 2 25 Nm (18.44 lb ft) Screws fixing handlebar support U-bolts to M10x60 50 Nm (36.88 lb ft)

  • Page 164: Removing The Fork Legs

    V7 II ABS Suspensions 17.Complete cap 18.Screw 19.Base with headstock 20.Ring nut 21.Fork upper plate 22.Washer 23.Nut 24.Rubber ring 25.Spacer 26.Cap 27.Nut 28.Ring 29.Right sleeve 30.Lower U-bolt 31.Upper U-bolt 32.Screw 33.Screw 34.O-ring 35.Chrome-plated cap Removing the fork legs The vehicle is equipped with a non adjustable fork. The operations described below are valid for both stanchions.
  • Page 165 V7 II ABS Suspensions • Undo and remove the two screws and collect the washers. • Move the instrument panel forwards. • Undo the upper sealing screw. • Undo the lower sealing screw. • Slide off the stem downwards by turning it slightly first in one direction then to the opposite direction.
  • Page 166 V7 II ABS Suspensions • Tighten the removed stanchion in a vice fitted with aluminium jaw caps in order to avoid damaging them. • Unscrew the upper closing cap. Pay attention to the possible thrust that the spring can cause to the loosened cap.
  • Page 167 V7 II ABS Suspensions • Drain out all the oil inside the stan- chion. NOTE FOR EASY DRAINAGE OF THE OIL INSIDE THE PISTON ROD, PRESS THE STANCHION IN THE WHEEL HOLDER SLEEVE TO PUMP OIL OUT. • Carefully check each part of the stan- chion and make sure that there are no damaged elements.
  • Page 168 V7 II ABS Suspensions • Slide the dust scraper off and upwards. • Remove the locking ring inside the fork leg using a thin screwdriver. CAUTION BE CAREFUL NOT TO DAMAGE THE FORK LEG RIM. • Slide off the bearing tube from the...
  • Page 169 V7 II ABS Suspensions 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.
  • Page 170 V7 II ABS Suspensions • 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. • Insert the cap and the well-lubricated sealing ring on the bearing tube.
  • Page 171 V7 II ABS Suspensions • Fit the dust scraper. • 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.

  • Page 172: Installing The Fork Legs

    V7 II ABS Suspensions • 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. Installing the fork legs •...
  • Page 173 V7 II ABS Suspensions SUSP - 173...
  • Page 174 V7 II ABS Suspensions Steering bearing RONT SUSPENSION TEERING pos. Description Type Quantity Torque Notes Stanchion cap 1 + 1 50 Nm (36.88 lb ft) Calliper bracket fixing screws M6x30 10 Nm (7.38 lb ft) Screws fixing fork stanchions to upper and low-...
  • Page 175 V7 II ABS Suspensions pos. Description Type Quantity Torque Notes Headstock fixing nut M23x1 50 Nm (36.88 lb ft) Handlebar U-bolt fastener screws M8x30 2 + 2 25 Nm (18.44 lb ft) Screws fixing handlebar support U-bolts to M10x60 50 Nm (36.88 lb ft)
  • Page 176 V7 II ABS Suspensions • Remove the upper plate from the front fork. • Adjust 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.

  • Page 177: Shock Absorbers

    V7 II ABS Suspensions Rear Shock absorbers EAR SUSPENSION pos. Description Type Quantity Torque Notes Upper screw fastening shock absorber to M6x35 10 Nm (7.38 lb ft) Loctite 243 frame SUSP - 177...
  • Page 178 V7 II ABS Suspensions pos. Description Type Quantity Torque Notes Lower pin fastening left shock absorber to M10x1.5 35 Nm (25.81 lb ft) swingarm Stud bolt fixing right shock absorber to rear M12x1.5 35 Nm (25.81 lb ft) Screw fastening right shock absorber to stud M6x18 10 Nm (7.38 lb ft)
  • Page 179 INDEX OF TOPICS CHAS HASSIS...

  • Page 180: Front Wheel

    V7 II ABS Chassis Wheels Front wheel RONT WHEEL pos. Description Type Quantity Torque Notes Front wheel axle M18x1.5 80 Nm (59.00 lb ft) Front brake disc fixing screw M8x20 25 Nm (18.44 lb ft) Loctite 243 ABS-sensor fixing stud bolt 6 Nm (4.43 lb ft)
  • Page 181 V7 II ABS Chassis • Loosen the two wheel pin locking screws; • Unscrew and remove the wheel pin; • Working on the opposite side, remove the left spacer; NOTE DURING REFITTING, PAY ATTENTION TO THE CORRECT POSITIONING OF THE SPACER WHICH MUST BE INSER- TED IN THE DUST SEAL UNTIL IT REACHES THE BEAR- •...

  • Page 182: Rear Wheel

    V7 II ABS Chassis • Remove the dust seal from both sides • Using a generic bearing extractor remove the bearings from both sides Rear wheel EAR WHEEL pos. Description Type Quantity Torque Notes Rear wheel axle nut up to frame se- M16x1.5...
  • Page 183 V7 II ABS Chassis • Remove the screw fixing the right-hand rear right shock absorber and pull it from the pin on the drive shaft • Remove the screw and the relative nut fixing the left rear shock absorber •...
  • Page 184 V7 II ABS Chassis • Unscrew and remove the fixing screw of the calliper holder. • Remove the wheel pin and collect the spacer. • Remove the complete rear brake cal- liper support • Remove the rear wheel PLACE A SUPPORT UNDER THE SWINGARM TO AVOID...
  • Page 185 V7 II ABS Chassis • Working on the left side, remove the spacer; NOTE DURING REFITTING, PAY ATTENTION TO THE CORRECT POSITIONING OF THE SPACER WHICH MUST BE INSER- TED IN THE DUST SEAL UNTIL IT REACHES THE BEAR- •...
  • Page 186 V7 II ABS Chassis • Operate on the nipple (2) to adjust the relative spoke tension (1); - screw to tighten the spoke; - unscrew to loose the spoke; • The indicative tightening torque of the nipples is: - front wheel 3 Nm (2.21 lb ft) - rear wheel 4 Nm (2.95 lb ft).
  • Page 187 V7 II ABS Chassis pos. Description Type Quantity Torque Notes Nut fixing gearcase to swingarm 25 Nm (18.44 lb ft) Hold the stud bolt Pin fixing swingarm to gearbox M20x1 Fully home with no preload Lock nut on swingarm pin M20x1 50 Nm (36.88 lb ft)
  • Page 188 V7 II ABS Chassis (V7 SPECIAL / V7 STONE / V7 RACER / V7 STORNELLO) • Remove the fixing nut of the cable grommet plate and disconnect it from the swingarm • Remove the ABS sensor and the brake calliper •...
  • Page 189 V7 II ABS Chassis • Remove the screw and the relative nut fixing the left rear shock absorber • Remove the screw fixing the right-hand rear right shock absorber and pull it from the pin on the drive shaft •...
  • Page 190 V7 II ABS Chassis • Remove the wheel pin and collect the spacer. • Remove the rear brake calliper support • Remove the rear wheel. • Cut the sealing clamp and lift the fold- CAUTION PAY ATTENTION NOT TO CUT AND DAMAGE THE RUB- BER FOLDING •...
  • Page 191 V7 II ABS Chassis • Loosen the pins so that the oscillating swingarm can be removed from the gearbox. • Remove the shimming washer be- tween the swingarm right arm and the gearbox. Checking • Check that the universal joint is not damaged, the gear teeth inserting in the sleeve grooves and the grooves on the joint are not deformed or damaged;...
  • Page 192 V7 II ABS Chassis • Check that the sleeve outer toothing and internal grooves are not damaged. Bevel gears Removing • Undo the four nuts and collect the washers. • Slide off the gearcase together with the swingarm. • Slide off the sleeve from the pinion.
  • Page 193 V7 II ABS Chassis • Slide off the gear. Checking Gruppo pignone • Remove 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.
  • Page 194 V7 II ABS Chassis • Slide off the spacer. • Slide off the pinion. • Slide off the shim adjustment washer. • Slide off the O-ring. • Slide off the oil seal. • Slide of the tapered bearing from the case.
  • Page 195 V7 II ABS Chassis • Slide off the tapered bearing from the case. Controllo • Check that the pinion toothing is not damaged, worn or deformed; otherwise, replace the pair. • Check that both tapered bearings are not damaged, that the rollers are not damaged or worn;...
  • Page 196 V7 II ABS Chassis • Fit the external ring of the tapered bearings on the bevel pinion holder case 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).
  • Page 197 V7 II ABS Chassis • Fit the complete pinion on the case 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.
  • Page 198 V7 II ABS Chassis • Undo the screws and collect the wash- ers. • Remove the braking disc from the dril- led bolt. • Undo the screws and collect the plates and the wave washers. • Slide off the complete cover.
  • Page 199 V7 II ABS Chassis • 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. CHAS - 199...
  • Page 200 V7 II ABS Chassis • Slide off the bearing from the cover us- ing the suitable punch. • Remove the gaskets unit made up of paper/steel/paper or foamet/steel/foamet CAUTION PAY ATTENTION TO THE TYPE OF GASKETS PRESENT, AS DURING INSTALLATION THE SAME SOLUTION MUST BE INSTALLED •...
  • Page 201 V7 II ABS Chassis • Check that the drilled bolt tongues, where the anti-vibration rubbers operate, are not spoiled; that the surfaces of: the sealing ring; the bearing 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;...
  • Page 202 V7 II ABS Chassis • Apply suitable colours available in the market on the pinion teeth. • Install the same type of gaskets present during the removal, the composition paper/steel/ paper or foamet/steel/foamet • Fit the drilled bolt-crown unit cover and...
  • Page 203 V7 II ABS Chassis • 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 spacer thickness.
  • Page 204 V7 II ABS Chassis • 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. •...
  • Page 205 V7 II ABS Chassis • Fit the bearing on the cover using the suitable punch. • Fit the internal ring of the needle bear- ing on the drilled bolt using the suitable punch (19927900). • Insert the sealing ring in the drilled bolt.
  • Page 206 V7 II ABS Chassis • Fit the crown. • Fit the plates and tighten the screws. • Insert the washer. • Insert the washer. CHAS - 206...
  • Page 207 V7 II ABS Chassis • Fit the O-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.
  • Page 208 V7 II ABS Chassis Installing • Insert the sleeve and base on the bevel pinion of the gearcase. • Correctly insert the stud bolts of the gearcase in the holes of the swingarm . • Screw the nuts with the washers with- out locking them.
  • Page 209 V7 II ABS Chassis XHAUST SYSTEM pos. Description Type Quantity Torque Notes Exhaust pipe fixing nut to the engine 10 Nm (7.38 lb ft) Exhaust pipe fixing clamp screw to 10 Nm (7.38 lb ft) the compensator Compensator fixing clamp screw to 10 Nm (7.38 lb ft)
  • Page 210 V7 II ABS Chassis XHAUST SYSTEM pos. Description Type Quantity Torque Notes Screw fixing central manifold to 10 Nm (7.38 lb ft) bracket (Stornello) Lambda probe fastener M18x1.5 1 + 1 38 Nm (28.03 lb ft) Heat shield fixing screw 2 + 2 8 Nm (5.90 lb ft)
  • Page 211 V7 II ABS Chassis 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.Left plate 15.Right silencer clamp...
  • Page 212 V7 II ABS Chassis key: 1. Silencer 2. Left exhaust manifold 3. Central exhaust manifold 4. Right exhaust manifold 5. Fixing bracket 6. Bushing 7. Clip 8. Rubber ring 9. Silencer protection 10.Heat protection 11.Screw 12.Washer 13.Screw 14.Washer 15.Spring with rubber 16.Washer...
  • Page 213 V7 II ABS Chassis 22.Lambda probe 23.Nut 24.Heat shield protection 25.Screw Removing the tail pipe The engine and the exhaust system 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.
  • Page 214 V7 II ABS Chassis • Remove the fixing spring of the silenc- er to the central manifold. • Unscrew and remove the fixing screw of the silencer at the support bracket and recover the nut and the washer. • Remove the muffler.
  • Page 215 V7 II ABS Chassis • Remove the exhaust ring fixing nuts, taking care to recover the washers • Remove the spacers • Remove the ring nuts • Disconnect the left lambda probe con- nector CHAS - 215...
  • Page 216 V7 II ABS Chassis • Remove the starter motor to allow the removal of the left lambda probe wir- ing. • Disconnect the right Lambda probe connector and slide the cabling from the cable grommet • Loosen the clamps between the joint and the exhaust manifolds •...
  • Page 217 V7 II ABS Chassis • Undo and remove the screw fixing the central muffler to the support bracket. • Remove the central manifold. • Disconnect the connectors of the lamb- da probes (The procedure of the removal as shown in the...
  • Page 218 V7 II ABS Chassis • Remove the ring nut and the spacers. • Remove the right front manifold. Removing the lambda sensor (V7 SPECIAL / V7 STONE / V7 RACER) • Remove the starter motor • Disconnect the left lambda probe con- nector (1) •...
  • Page 219 V7 II ABS Chassis • Unscrew and remove the lambda probes (3) (V7 STORNELLO) • Disconnect the connectors of the lamb- da probes • Unscrew and remove the two lambda probes. CHAS - 219...
  • Page 220 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
  • Page 221 V7 II ABS Braking system SYSTEM pos. Description Type Quantity Torque Notes Screw fixing ABS control unit support 10 Nm (7.38 lb ft) to chassis key: BRAK SYS - 221...
  • Page 222 V7 II ABS Braking system 1. ABS ECU control unit 2. Front ABS sensor 3. Rear ABS sensor 4. Battery 5. Main relay 6. ECU 7. Instrument panel 8. K line (diagnosis) 9. Key 10.Fuses ABS ECU control unit pin configuration •...
  • Page 223 V7 II ABS Braking system Foreword key: 1. Rear brake calliper 2. Modulator 3. Front bleed valve 4. Front brake reservoir 5. Front brake callipers 6. Rear brake pump 7. Rear brake reservoir 8. ABS control unit front pump pipe 9.
  • Page 224 V7 II ABS Braking system 20.Brake pipe mounting plate 21.Pipes fixing plate 22.Screw 23.Clamp 24.Screw 25.Nut 26.Ring 27.Brake pipe support 28.Clip BRAK SYS - 224...
  • Page 225 V7 II ABS Braking system Operating diagram ABS functional diagram key 1. Front system circuit 2. Front brake pump 3. Front brake lever 4. Rear system circuit BRAK SYS - 225...
  • Page 226 V7 II ABS Braking system 5. Rear brake pump 6. Rear brake pedal control 7. ABS control unit 8. Rear brake calliper 9. Front Calliper 10.Front brake circuit intake solenoid valve (normally open) 11.Humidifier 12.Rear brake circuit intake solenoid valve (normally open) 13.Rear brake exhaust circuit solenoid valve (normally closed)
  • Page 227 V7 II ABS Braking system D - Pressure restored: by opening the inlet valve (10-12) momentarily, the pressure of the callipers (8-9) is increased until maximum deceleration is reached. Then, the system gives the control over the braking back to the rider.
  • Page 228 V7 II ABS Braking system Riding with an active ABS system • When starting the engine, the ABS warning light on the dashboard (4) lights up and flashed until reaching 5 km/h (3.1 mph), at this point it turns off.
  • Page 229 V7 II ABS Braking system Error detection logic foresees that for the errors to be diagnosed one or more conditions must persist within a given time. If during this given time one of the conditions is missing but then it comes back, the timer is reset and the system is no longer able to diagnose the error.
  • Page 230 V7 II ABS Braking system Abs screen pages ECU INFO screen page This screen page shows general data regarding the control unit, for example software type, map- ping, control unit programming date PARAMETERS screen page This screen page shows the parameters meas- ured by the several sensors (engine revs, engine temperature, etc.) or values set by the control unit...
  • Page 231 V7 II ABS Braking system ACTIVATION screen page This screen page is used to delete errors in the control unit memory and to activate some systems controlled by the control unit. ACTIVATION P.A.D.S. characteristic Value/example Unit of Notes measure ment...
  • Page 232 V7 II ABS Braking system P.A.D.S. characteristic. Value/example Units of Notes measure ment Low power supply voltage C1058 High power supply voltage C1059 Configuration error C1089 CAN error U2921 Controller error CAN error U2922 Line failure (busoff) CAN error U2924...
  • Page 233 V7 II ABS Braking system • Select an error and show the Ambient parameter error(where provided). • Repeat the operation by selecting each error and showing the corresponding Ambient parameter error (where provi- ded). • Go to the page Report and then on Print and select the virtual PDF printer.
  • Page 234 V7 II ABS Braking system • If there is no PDF printer, there are several free programs, ask the infor- mation systems to install it. • Name the file with a name that contains the main information of the vehicle and the analysed component e.g.
  • Page 235 V7 II ABS Braking system • Remove the fixing screw from the volt- age regulator that holds the support bracket of the ABS control unit. • Operating from the left side of the mo- torcycle, remove the ABS modulator •...
  • Page 236 V7 II ABS Braking system Rear brake calliper EAR BRAKE CALLIPER pos. Description Type Quantity Torque Notes Rear brake calliper fixing screw M8x30 25 Nm (18.44 lb ft) Drilled screw for brake pipe on cal- 25 Nm (18.44 lb ft)
  • Page 237 V7 II ABS Braking system 1. Brake calliper mounting plate 2. Bushing 3. Pin 4. Screw 5. Spacer 6. Rear brake calliper 7. Brake pads copy 8. Bleed valve and cover kit 9. Pins and spring kit Removal • Obtain a special container and empty the system •...
  • Page 238 V7 II ABS Braking system Front brake calliper RONT BRAKE SYSTEM pos. Description Type Quantity Torque Notes Brake pump U-Bolt fixing screw 10 Nm (7.38 lb ft) Front brake calliper fixing screw M10x30 50 Nm (36.88 lb ft) Fixing screw for brake fluid pipe on pump and 25 Nm (18.44 lb ft)
  • Page 239 V7 II ABS Braking system 1. Front brake pump 2. Washer 3. Spacer 4. Screw 5. Stop switch 6. Pump cover 7. U-bolt with screws 8. Complete lever pin 9. Brake lever 10.Bleed valve and cover kit 11.Pins and spring kit 12.Spring...
  • Page 240 V7 II ABS Braking system • Remove the calliper Rear brake disc EAR WHEEL pos. Description Type Quantity Torque Notes Rear wheel axle nut up to frame se- M16x1.5 120 Nm (88.51 lb ft) rial number ZGULWS00XEM200368 Rear wheel axle nut up to frame se- M16x1.5...
  • Page 241 V7 II ABS Braking system Removal • Remove the rear wheel • Remove the six fixing screws (1) of the tone wheel and the front disc • Remove the tone wheel (2) • Remove the brake disc (3) DURING REFITTING, APPLY LOCTITE 243 ON THE THREAD OF THE BRAKE DISC SCREWS (1).
  • Page 242 V7 II ABS Braking system • The following operations are to be car- ried out with brake disc fitted on the wheel. • Check the disc for wear by measuring the minimum thickness with a micro- meter in different points. If the mini-...
  • Page 243 V7 II ABS Braking system Removal • Remove the rear wheel • Remove the six fixing screws (1) of the tone wheel and the front disc • Remove the tone wheel (2) • Remove the brake disc (3) DURING REFITTING, APPLY LOCTITE 243 ON THE THREAD OF THE BRAKE DISC SCREWS (1).

  • Page 244: Front Brake Pads

    V7 II ABS Braking system • The following operations must be car- ried out with the brake discs fitted on the wheel; they refer to a single disc, but are valid for both. • Check the disc for wear by measuring the minimum thickness with a micro- meter in different points.

  • Page 245: Rear Brake Pads

    V7 II ABS Braking system • Collect the protection plate. • Remove the brake pads Rear brake pads Removal • Remove the rear brake calliper • Remove the screws locking the brake pads BRAK SYS - 245...
  • Page 246 V7 II ABS Braking system • Remove the brake pads Bleeding the braking system Front Any air trapped in the hydraulic circuit acts as a cushion, absorbing much of the pressure applied by the brake pump and minimising the braking power of the calliper.
  • Page 247 V7 II ABS Braking system • Insert the transparent plastic pipe in the front brake calliper bleed valve and slide the other end of this pipe in a con- tainer to collect the fluid. • Remove the front brake fluid reservoir cap.
  • Page 248 V7 II ABS Braking system • Remove the rubber protection cover from the bleed valve. • Insert the transparent plastic pipe in the rear brake calliper bleed valve and insert the other end of this pipe into a container to collect the fluid.
  • Page 249 V7 II ABS Braking system Front brake pump RONT BRAKE SYSTEM pos. Description Type Quantity Torque Notes Brake pump U-Bolt fixing screw 10 Nm (7.38 lb ft) Front brake calliper fixing screw M10x30 50 Nm (36.88 lb ft) Fixing screw for brake fluid pipe on pump and 25 Nm (18.44 lb ft)
  • Page 250 V7 II ABS Braking system • Remove the two brake pump fixing screws • Remove the brake pump CAUTION DURING REFITTING FILL UP THE BRAKE SYSTEM WITH THE RELATIVE BLEEDING PROCEDURE TO AVOID AIR BUBBLES IN THE SYSTEM Rear brake pump EAR BRAKE LEVER pos.
  • Page 251 V7 II ABS Braking system pos. Description Type Quantity Torque Notes Rear brake rod fixing lock nut Manual Brake pump fixing screws M6x25 10 Nm (7.38 lb ft) IDER FOOTREST EAR BRAKE LEVER pos. Description Type Quantity Torque Notes Screw fastening right hand rider foot- M8x20 20 Nm (14.75 lb ft)
  • Page 252 V7 II ABS Braking system • Take the pump from the brake pump shaft • Remove the brake pipe by acting on the fitting and remove the complete pump CAUTION DURING REFITTING FILL UP THE BRAKE SYSTEM WITH THE RELATIVE BLEEDING PROCEDURE TO AVOID AIR...
  • Page 253 INDEX OF TOPICS BODYW ODYWORK...
  • Page 254 V7 II ABS Bodywork ODYWORK CENTRAL SECTION ADDLE pos. Description Type Quantity Torque Notes Saddle release block fixing screw M6x25 10 Nm (7.38 lb ft) Side fairing fixing screw M5x9 4 Nm (2.95 lb ft) ODYWORK CENTRAL SECTION ADDLE pos.
  • Page 255 V7 II ABS Bodywork pos. Description Type Quantity Torque Notes Side fairing fixing screw M5x9 4 Nm (2.95 lb ft) ODYWORK CENTRAL SECTION ADDLE pos. Description Type Quantity Torque Notes Saddle release block fixing screw (Stornello) M5x12 5 Nm (3.69 lb ft)
  • Page 256 V7 II ABS Bodywork EAR LIGHTS pos. Description Type Quantity Torque Notes Screw fastening taillight support to M5x14 4 Nm (2.95 lb ft) mudguard Rear turn indicator fixing screw 5 Nm (3.69 lb ft) ARROZZERIA ARTE OSTERIORE ORTATARGA Pos. Descrizione Tipo Quantità...
  • Page 257 V7 II ABS Bodywork EAR MUDGUARD pos. Description Type Quantity Torque Notes Rear mudguard front and central fixing screw 10 Nm (7.38 lb ft) (Special/Stone/Racer) Screw fixing rear mudguard bracket to chassis 10 Nm (7.38 lb ft) (Stornello) Rear mudguard side fixing screw (Special/ M8x30 20 Nm (14.75 lb ft)
  • Page 258 V7 II ABS Bodywork pos. Description Type Quantity Torque Notes Screw fixing license plate holder to mudguard 3 Nm (2.21 lb ft) reinforcement (Special/Stone/Racer) M5x20 UEL TANK pos. Description Type Quantity Torque Notes Rear tank fixing screw 25 Nm (18.44 lb ft) Screw fastening cap flange to tank 3 Nm (2.21 lb ft)
  • Page 259 V7 II ABS Bodywork Disassembling the lock • Remove the left side fairing. • Remove the fork spring • Remove the cable support plate • Extract the ignition switch assembly externally Taillight assy. (V7 STORNELLO) BODYW - 259...
  • Page 260 V7 II ABS Bodywork • Remove the saddle. • Remove the windscreen of the rear mud guard. • Remove the two clamps (1). • Undo and remove the two fixing screws (2). • Remove the light unit complete from the support bracket.
  • Page 261 V7 II ABS Bodywork • Remove the side fairing fixing screw • Delicately unhook the pins (2) from the relative retaining rubber clamps • Remove the side fairing. (V7 RACER) • Remove the side fairing fixing screw • Remove the side fairing.
  • Page 262 V7 II ABS Bodywork • Undo and remove the three fixing screws (3) of the side fairing. • Remove the side fairing (4), recovering the three spacers (5) and the three washers (6). License plate holder (V7 STORNELLO) • Remove the saddle.
  • Page 263 V7 II ABS Bodywork • Remove the license plate holder (4). Rear mudguard (V7 SPECIAL / V7 STONE / V7 RACER) • Remove the saddle • Remove the upper central screw (1) that secures the mudguard to the frame •...
  • Page 264 V7 II ABS Bodywork • 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...
  • Page 265 V7 II ABS Bodywork • Recover the washer (3), the washer (4) and the two washers (5). • Lock the nut with an appropriate wrench as indicated in the figure. • Undo and remove the fixing screw (6). • Recover the washer (7), and the two spacers (8) and (9).

  • Page 266: Fuel Tank

    V7 II ABS Bodywork Splash guard • Remove the lower screws (1) • Remove the upper screws (2) taking care to recover the nuts • Remove the splash guard, pulling it to the rear Fuel tank (V7 SPECIAL / V7 STONE / V7 STORNELLO)
  • Page 267 V7 II ABS Bodywork • Unscrew and remove the rear screw. • 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 •...
  • Page 268 V7 II ABS Bodywork • Remove the fuel tank by sliding it off and back. (V7 RACER) • Remove the screws that fix the horns. • Unscrew and remove the rear screw. • Partially lift the fuel tank in order to be able to disconnect the fuel hose fitting, avoiding damaging it.
  • Page 269 V7 II ABS Bodywork • Disconnect the connector. • Remove the fuel breather pipe. • Remove the fuel tank by sliding it off and back. BODYW - 269...
  • Page 270 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 271 V7 II ABS Pre-delivery Carry out the listed checks before delivering the motorcycle. WARNING HANDLE FUEL WITH CARE. Aesthetic inspection - Paintwork - Fitting of Plastic Parts - Scratches - Dirt Tightening torques inspection - Safety fasteners: front and rear suspension unit...

  • Page 272: Road Test

    V7 II ABS Pre-delivery CAUTION TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE. INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST USED SHORTENS BATTERY LIFE. CAUTION WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG- ATIVE ONE, AND PERFORM THE REVERSE OPERATION DURING REMOVAL.
  • Page 273 V7 II ABS Pre-delivery - Response to throttle control - Stability when accelerating and braking - Front and rear brake efficiency - Front and rear suspension efficiency - Abnormal noise Static test Static check after test drive: - Restarting when warmed up...
  • Page 274 V7 II ABS Pre-delivery WO SEATER VERSION pos. Description Type Quantity Torque Notes Passenger handgrip front fixing 10 Nm (7.37 lbf ft) screw Passenger handgrip rear fixing nut 25 Nm (18.44 lbf ft) Passenger footrest mounting bracket M8x16 25 Nm (18.44 lbf ft)
  • Page 275 V7 II ABS Pre-delivery • Fit the exhaust mounting plate preset for fixing the passenger footrest, so as to turn the vehicle into a two seater version. • Tighten the three fastener screws to the specified torque. • Fit the countersunk screw with hexag- onal hole on "C"...
  • Page 276 V7 II ABS Pre-delivery • Lock the bolt with the Seeger ring. NOTE REPEAT THE STEPS TO FIT THE PASSENGER FOOTPEG ON THE OPPOSITE SIDE. Rotazione ammortizzatori e posizionamento maniglie passeggero • Remove the two shock absorber fixing screws. •...
  • Page 277 V7 II ABS Pre-delivery SELLA ODYWORK CENTRAL SECTION ADDLE pos. Description Type Quantity Torque Notes Saddle release block fixing screw M6x25 10 Nm (7.38 lb ft) Throttle body cover fastener screw M5x14 4 Nm (2.95 lb ft) Side fairing fixing screw M5x9 4 Nm (2.95 lb ft)
  • Page 278 V7 II ABS Pre-delivery • Place the two-seat saddle. PRE DE - 278...
  • Page 279 ABS: 221, 229, 230 Air filter: 55, 58, 59, 61 Air temperature sensor: 127 Battery: 93, 99 Brake: 236, 238, 240, 242, 244, 245, 249, 250 Brake calliper: 236, 238 Brake disc: 240, 242 Brake lever: Brake pads: 244, 245 Brake pump: 249, 250 Bulbs: Clutch: 124...
  • Page 280 Instrument panel: 127 License plate holder: 262 Maintenance: 8, 48 Maintenance Table: Mudguard: 263 Oil filter: 52 Oil pressure sensor: 122 Rear wheel: 182 Recommended products: 42 Run/Stop switch: 128 Saddle: Scheduled maintenance: 48 Shock absorbers: 177 Side stand: 125 Side stand sensor: 125 Spark plugs: Speed sensor: 99...

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