Page 1 SERVICE STATION MANUAL 2Q000297 V7 III 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 III 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 III ABS Characteristics Brake and clutch fluid BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAINTED SURFACES. WHEN SERVICING THE BRAKING OR THE CLUTCH SYSTEM PROTECT THESE COMPONENTS WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THESE SYSTEMS.
Page 9 REASSEMBLING COMPONENTS CAUTION BEARINGS MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE, 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 III ABS Characteristics CHASSIS NUMBER The chassis number is stamped on the right hand side of the headstock. This number consists of numbers and letters, as in the example shown below. ZGULD00016MXXXXXX KEY: ZGU: WMI (World manufacturer identifier) code; LD: model;...
Page 12 V7 III ABS Characteristics Specification Desc./Quantity Compression ratio 10.5 +/- 0.5: 1 Start up Electric Engine idle speed 1,250 +/- 100 rpm Clutch dry single-disc clutch with flexible coupling Lubrication Pressure-fed, controlled by valves and trochoidal pump Air filter cartridge-type dry filter Cooling Transmission GEARBOX...
Page 13: Warning Lights
V7 III ABS Characteristics WARNING LIGHTS Specification Desc./Quantity Gearbox in neutral Turn indicators Fuel reserve High beam light General alarm MI warning light ABS Warning Light MGCT warning light Frame and suspensions SIZES A Specification Desc./Quantity Size A 692 mm (27.24 in) Size B 186 mm (7.32 in) FRAME...
Page 14: Wheels And Tyres
V7 III ABS Characteristics Wheels and tyres WHEEL RIMS Specification Desc./Quantity Type (Special/Racer/Anniversario) with spokes with alloy rims, for tyres with inner tubes Type (Stone) Alloy wheels for tubeless tyres Front 2.5''x18'' Rear 3.50" x 17'' TYRES Specification Desc./Quantity Front tyre PIRELLI SPORT DEMON Front (size) 100 / 90 - 18 56H...
Page 15 V7 III ABS Characteristics Front side RONT SUSPENSION TEERING Pos. Description Type Quantity Torque Notes Screws fastening stanchion on upper plate M8x35 25 Nm (18.44 lb ft) Steering head fastening bushing 100 Nm (73.76 lb ft) Steering headstock lock nut 50 Nm (36.88 lb ft) Pre-torque 60 Nm (44.25 lb ft) Headstock counter-lock ring...
Page 16 V7 III ABS Characteristics Pos. Description Type Quantity Torque Notes Connector plate fastening screw M6x16 10 Nm (7.38 lb ft) Screws fastening stanchion on lower plate 45 Nm (33.19 lb ft) Pumping unit fastening screw 50 Nm (36.88 lb ft) NSTRUMENT PANEL Pos.
Page 17 V7 III ABS Characteristics NSTRUMENT PANEL Pos. Description Type Quantity Torque Notes Instrument cluster cover fastening screws Self-tap- 1.2 - 1.5 Nm (0.89 - ping 1.11 lb ft) 4.2x19 Screws fastening instrument cluster to support Self-tap- 1.2 - 1.5 Nm (0.88 - bracket ping 1.11 lb ft)
Page 18 V7 III ABS Characteristics ANDLEBAR AND ONTROLS Pos. Description Type Quantity Torque Notes Screw fixing handlebar support U-bolts to 50 Nm (36.88 lb ft) steering plate Handlebar U-bolt fastener screws 25 Nm (18.44 lb ft) Mirror fixing Manual Light switch fastening screws SWP 5 1.5 Nm (1.11 lb ft) Throttle cable cover fastening screws...
Page 19 V7 III ABS Characteristics RONT BRAKE MASTER CYLINDER Pos. Description Type Quantity Torque Notes Front brake master cylinder U-bolt fixing 10 Nm (7.38 lb ft) screws Brake light switch fastening screws 3 Nm (2.21 lb ft) RONT LIGHTS Pos. Description Type Quantity Torque...
Page 20 V7 III ABS Characteristics Pos. Description Type Quantity Torque Notes Front turn indicators fastening screws 5 Nm (3.69 lb ft) Screws fastening the headlight support strips 10 Nm (7.38 lb ft) RONT MUDGUARD Pos. Description Type Quantity Torque Notes Screws fastening the stabiliser plate to the fork 15 Nm (11.06 lb ft) Loctite 243 Screw fastening the mudguard to the stabiliser...
Page 21 V7 III ABS Characteristics RONT WHEEL Pos. Description Type Quantity Torque Notes Wheel axle 80 Nm (59.00 lb ft) Front brake disc fixing screws 25 Nm (18.44 lb ft) Loctite 243 ABS-sensor fixing stud bolt 6 Nm (4.43 lb ft) Pre-permeated Cable gland nut 6 Nm (4.43 lb ft)
Page 22 V7 III ABS Characteristics Central part HASSIS Pos. Description Type Quantity Torque Notes Screws fastening the tank support 25 Nm (18.44 lb ft) buffers to the frame Front cradle fixing screws 50 Nm (36.88 lb ft) Screw fastening the stand cross- 50 Nm (36.88 lb ft) Pre-permeated piece to the cradles...
Page 23 V7 III ABS Characteristics OOTRESTS Pos. Description Type Quantity Torque Notes Screws fastening rider footrest support to 25 Nm (18.44 lb ft) Loctite 243 the frame Screws fastening passenger footrest sup- 25 Nm (18.44 lb ft) Pre-permeated port to the frame Anti-sliding pin 10 Nm (7.38 lb ft) Loctite 243...
Page 24 V7 III ABS Characteristics ASSENGER FOOTRESTS Pos. Description Type Quantity Torque Notes Footrest support fastening screw 25 Nm (18.44 lb ft) Pre-permeated Screws fastening passenger footrest sup- 25 Nm (18.44 lb ft) Pre-permeated port to the frame EAR LEVER Pos. Description Type Quantity...
Page 25 V7 III ABS Characteristics IDER FOOTREST EAR SHIFT LEVER Pos. Description Type Quantity Torque Notes Screw fastening left hand rider foot- M8x20 25 Nm (18.44 lb ft) Loctite 243 rest mounting plate to cradle Preselector lever fixing screw M6x20 10 Nm (7.38 lb ft) Gearbox lever fixing screws M6x20 10 Nm (7.38 lb ft)
Page 26 V7 III ABS Characteristics EAR BRAKE MASTER CYLINDER Pos. Description Type Quantity Torque Notes Brake master cylinder reservoir fixing 10 Nm (7.38 lb ft) screws Brake light switch fastening 10 Nm (7.38 lb ft) Loctite 243 Rear brake lever peg fastening 20 Nm (14.75 lb ft) Loctite 243 Rear brake lever fixing pin...
Page 27 V7 III ABS Characteristics IDE STAND Pos. Description Type Quantity Torque Notes Side stand retainer pin 10 Nm (7.38 lb ft) Lock washer fastening on side stand pin 30 Nm (22.13 lb ft) Side stand switch fastening screws 6 Nm (4.43 lb ft) Pre-permeated CHAR - 27...
Page 28 V7 III ABS Characteristics UEL TANK Pos. Description Type Quantity Torque Notes Screws fastening fuel pump to fuel tank 5 Nm (3.69 lb ft) Pre-permeated Rear tank fastening screw 25 Nm (18.44 lb ft) ILTER BOX Pos. Description Type Quantity Torque Notes Filter box fastening screws...
Page 29 V7 III ABS Characteristics Pos. Description Type Quantity Torque Notes Air filter cover fastening screws SWP M5 3 Nm (2.21 lb ft) Filter casing/frame fastening screw SWP M5 3 Nm (2.21 lb ft) ENTRAL BODYWORK Pos. Description Type Quantity Torque Notes Starter motor cover fastening screws 4 Nm (2.95 lb ft)
Page 30 V7 III ABS Characteristics OCK KIT Pos. Description Type Quantity Torque Notes (Shear head) screw fixing ignition At the point of failure Loctite 243 lock Ignition lock fixing screw 25 Nm (18.44 lb ft) Pre-permeated Saddle release block fixing screws 10 Nm (7.38 lb ft) CHAR - 30...
Page 31 V7 III ABS Characteristics XHAUST SYSTEM Pos. Description Type Quantity Torque Notes Lambda probes fastener 38 Nm (28.03 lb ft) Screws fastening heat shields to 8 Nm (5.90 lb ft) Pre-permeated manifolds Screws fastening heat shields to si- 8 Nm (5.90 lb ft) Pre-permeated lencers Screws fastening silencers to frame...
Page 32 V7 III ABS Characteristics Back side WINGARM Pos. Description Type Quantity Torque Notes Pins fixing swingarm to gearbox Fully home with no preload Lock washer fastening on pin 50 Nm (36.88 lb ft) Hold the pin Nut fixing gearcase to swingarm 25 Nm (18.44 lb ft) Hold the pin Pin fixing the rear calliper holding...
Page 33 V7 III ABS Characteristics EAR SHOCK ABSORBERS Pos. Description Type Quantity Torque Notes Top rear shock absorber fixing screws 10 Nm (7.38 lb ft) Pre-permeated Pin fastening left shock absorber to the swing- 35 Nm (25.81 lb ft) Pin fastening the shock absorber to gearbox 35 Nm (25.81 lb ft) Screw fastening right shock absorber to pin 10 Nm (7.38 lb ft)
Page 34 V7 III ABS Characteristics EAR BRAKE CALLIPER Pos. Description Type Quantity Torque Notes Rear brake calliper fixing screw 25 Nm (18.44 lb ft) EAR WHEEL Pos. Description Type Quantity Torque Notes Rear brake disc fastening screws 25 Nm (18.44 lb ft) Loctite 243 Rear wheel axle fastener pin + nut 120 Nm (88.51 lb ft)
Page 35 V7 III ABS Characteristics EAR LIGHT UNIT Pos. Description Type Quantity Torque Notes Screws fastening taillight support to the mud- 4 Nm (2.95 lb ft) guard Rear turn indicator fastener nut 6 Nm (4.43 lb ft) Reflector fixing nut retainer to the support 4 Nm (2.95 lb ft) Screw fastening license plate mounting on SWP 5...
Page 36 V7 III ABS Characteristics EAR MUDGUARD Pos. Description Type Quantity Torque Notes Rear mudguard fixing screws 20 Nm (14.75 lb ft) Front and centre fastening screw rear mud- 10 Nm (7.38 lb ft) guard Rear splash guard fastening screws 10 Nm (7.38 lb ft) CHAR - 36...
Page 37 V7 III ABS Characteristics ECONDARY AIR SYSTEM Pos. Description Type Quantity Torque Notes Red valve cover fixing SHC screws M5x16 3-4 Nm (2.21-2.95 lb ft) RONT ELECTRICAL SYSTEM Pos. Description Type Quantity Torque Notes Voltage regulator and horn fastening screws 10 Nm (7.38 lb ft) CHAR - 37...
Page 38 V7 III ABS Characteristics ENTRAL ELECTRICAL SYSTEM Pos. Description Type Quantity Torque Notes Coils fastening nuts 10 Nm (7.38 lb ft) EAR ELECTRICAL SYSTEM Pos. Description Type Quantity Torque Notes Control unit cable grommet fastening screw 4 Nm (2.95 lb ft) Thread-form- ing screws Battery holder bracket fastening screws...
Page 39 INDEX OF TOPICS S-TOOLS PECIAL TOOLS...
Page 40: Special Tools
V7 III ABS Special tools SPECIAL TOOLS Stores code Description 021009Y Engine axial clearance check tool 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 Extractor for external ring of gearcase...
Page 41 V7 III ABS Special tools Stores code Description 19.92.62.00 Punch for bearing on bevel gear set pin- 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 42 INDEX OF TOPICS MAIN AINTENANCE...
Page 43: Scheduled Maintenance Table
V7 III 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 44: Transmission Fluid
V7 III ABS Maintenance km x 1,000 (mi x 1,000) 1.5 (0.9) 10 (6.2) (12.4) (18.6) (24.9) (31.1) (37.3) Engine oil pressure warning light (4) Filter box drain plug Fuel lines (3) Brake pipes Clutch wear Brake pads wear (7) Labour time (minutes) SCHEDULED MAINTENANCE TABLE ONLY FOR THE ASIA/PACIFIC MARKET SCHEDULED MAINTENANCE TABLE...
Page 45 V7 III 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 cap/dipstick opening (1). • If the oil is lower than specified, top-up until it reaches the cap/dipstick hole (1).
Page 46: Engine Oil
V7 III ABS Maintenance • Screw and tighten the caps (1 - 2). Engine oil Check CAUTION ENGINE MUST BE WARM TO CHECK ENGINE OIL LEVEL. THE ENGINE MUST BE WARM TO CHECK OIL LEVEL AND THE FILLER PLUG / DIPSTICK FULLY INSERTED BUT NOT SCREWED IN.
Page 47 V7 III ABS Maintenance The difference between 'MAX' and 'MIN' marks is approx. 400 cm³ (24.41 cu.in) • The oil level is correct when it is close to the 'MAX' mark. Add engine oil if required: • Unscrew and remove the filler plug/oil dipstick. •...
Page 48: Engine Oil Filter
V7 III ABS Maintenance DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT. DISPOSE OF ENGINE OIL IN A SEALED CONTAINER AND TAKE IT TO YOUR SUPPLIER OR TO THE NEAREST USED OIL COLLECTION CENTRE. Engine oil filter NOTE NEVER REUSE AN OLD FILTER. •...
Page 49: Air Filter
V7 III ABS Maintenance • Unscrew and remove the filler plug (1). • Drain the oil into the container; allow several minutes for oil to drain out com- pletely. • Check and if necessary, replace the sealing washers of drainage plug (2). •...
Page 50: Throttle Body Removal
V7 III ABS Maintenance • Remove the air-box cover fixing screw • Remove the air-box cover • Extract the air filter Throttle body removal • Remove the clip clamp fixing the sleeve to the filter box CAUTION DURING REFITTING, REPLACE THE CLIP CLAMP •...
Page 51 V7 III 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 • Remove the clip clamp fixing the throt- tle body to the filter box •...
Page 52 V7 III ABS Maintenance • Remove the throttle body guard • Loosen the gas cables fixing nuts on the throttle body and unhook them • Remove the throttle body MAIN - 52...
Page 53 V7 III ABS Maintenance Air filter housing ILTER BOX Pos. Description Type Quantity Torque Notes Filter box fastening screws SWP M5 3 Nm (2.21 lb ft) Air filter cover fastening screws SWP M5 3 Nm (2.21 lb ft) Filter casing/frame fastening screw SWP M5 3 Nm (2.21 lb ft) Air filter housing removal...
Page 54 V7 III 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 55 V7 III 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 - 55...
Page 56 V7 III 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 57: Checking The Valve Clearance
V7 III 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 58 V7 III ABS Maintenance • Remove the spark plug cover (2) • Disconnect the spark plug cap (3) • Unscrew and remove the two spark plug support retaining screws (4) • Retrieve the two spacers (5) • Push the spark plug cable complete with support, as indicated in the figure, towards the front of the vehicle MAIN - 58...
Page 59 V7 III ABS Maintenance • Unscrew and remove the three head cover retaining screws (6) • Remove the head cover (7) • Unscrew the spark plug (8) and re- move it REMOVE THE RIGHT HAND CYLINDER SPARK PLUG TOO SO THAT IT IS POSSIBLE TO TURN THE ENGINE OVER MANUALLY, EN- GAGE FIRST GEAR AND ROTATE THE REAR WHEEL...
Page 60 V7 III ABS Maintenance 0.10 mm (0.0039 in) Exhaust valve clearance 0.15 mm (0.0059 in) • Loosen the lock nut, adjust the clear- ance by acting on the adjuster until reaching the prescribed values • Tighten the lock nut • To perform the valve clearance of the right cylinder, it is necessary to bring the cylinder to the top dead centre, ro-...
Page 61 V7 III ABS Maintenance RONT BRAKE MASTER CYLINDER Pos. Description Type Quantity Torque Notes Front brake master cylinder U-bolt fixing 10 Nm (7.38 lb ft) screws Brake light switch fastening screws 3 Nm (2.21 lb ft) EAR BRAKE CALLIPER Pos. Description Type Quantity...
Page 62 V7 III ABS Maintenance EAR BRAKE MASTER CYLINDER Pos. Description Type Quantity Torque Notes Brake master cylinder reservoir fixing 10 Nm (7.38 lb ft) screws Brake light switch fastening 10 Nm (7.38 lb ft) Loctite 243 Rear brake lever peg fastening 20 Nm (14.75 lb ft) Loctite 243 Rear brake lever fixing pin...
Page 63 V7 III ABS Maintenance 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) Loctite 243 Screw fastening rider footrest mount-...
Page 64 V7 III ABS Maintenance If the fluid does not reach at least the "MIN" refer- ence mark: CAUTION FLUID LEVEL DECREASES GRADUALLY AS BRAKE PADS WEAR DOWN. • Check the brake pads and discs for wear. • If the pads and/or the disc do not need replacing, top-up the fluid (RACER) REAR BRAKE CHECK...
Page 65 V7 III ABS Maintenance • Remove the brake fluid reservoir cover • Remove the inner cover (3) • Remove the diaphragm (4) • Top up the brake fluid reservoir. (SPECIAL/STONE/ANNIVERSARIO) REAR BRAKE • Unscrew and remove the two fastening screws (1) on the brake fluid reservoir cover (2).
Page 66 V7 III ABS Maintenance • Remove the brake fluid reservoir cover • Remove the inner cover (3) • Remove the diaphragm (4) • Top up the brake fluid reservoir. (RACER) • Remove the brake fluid reservoir cap • Remove the diaphragm (2) •...
Page 67 V7 III ABS Maintenance AVOID PROLONGED AIR EXPOSURE OF THE BRAKE FLUID. BRAKE FLUID IS HYGROSCOPIC AND ABSORBS MOISTURE WHEN IN CONTACT WITH AIR. LEAVE THE BRAKE FLUID RESER- VOIR OPEN ONLY FOR THE TIME NEEDED TO COMPLETE THE TOPPING-UP PROCEDURE. TO AVOID SPILLING FLUID WHILE TOPPING-UP, KEEP THE TANK PARALLEL TO THE RESER- VOIR EDGE (IN HORIZONTAL POSITION).
Page 68 V7 III ABS Maintenance • Insert a dial gauge on the tool, as indi- cated, to be able to measure the clear- ance. • Reset the dial gauge. • Screw the central nut until the dial gauge indicates a value of 0.5 mm (0.020 in) (the value indicated on the dial gauge is expressed in hundredths of a millimetre) and the loosen com-...
Page 69 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 70 V7 III ABS Electrical system RONT ELECTRICAL SYSTEM Pos. Description Type Quantity Torque Notes Voltage regulator and horn fastening screws 10 Nm (7.38 lb ft) ENTRAL ELECTRICAL SYSTEM Pos. Description Type Quantity Torque Notes Coils fastening nuts 10 Nm (7.38 lb ft) ELE SYS - 70...
Page 71 V7 III ABS Electrical system EAR ELECTRICAL SYSTEM Pos. Description Type Quantity Torque Notes Control unit cable grommet fastening screw 4 Nm (2.95 lb ft) Thread-form- ing screws Battery holder bracket fastening screws Manual Fuse box bracket fastening screws 4 Nm (2.95 lb ft) Battery holder plate fastening screws 25 Nm (18.44 lb ft) Pre-perme-...
Page 72 V7 III ABS Electrical system Components arrangement key: 1. Instrument panel 2. Coil 3. Fuel pump 4. Injector ELE SYS - 72...
Page 73 V7 III ABS Electrical system 5. Taillight 6. MIU G3 Control Unit 7. Engine speed sensor 8. Starter motor 9. Engine speed sensor 10.Fuses 11.Battery 12.Head temperature sensor 13.Instrument panel air sensor 14.Headlamp 15.Voltage regulator 16.Alternator 17.Oil pressure sensor 18.Lambda probes Electrical system installation INTRODUCTION Scope and applicability...
Page 74 V7 III ABS Electrical system • 1 Black sheath • 7 ABS Cable grommets • 1 connector clip Motorcycle division The wiring timing is subdivided in three essential sections, as indicated in the figure. 1. Front section 2. Central section 3.
Page 75 V7 III ABS Electrical system • Check the coils connection (and their correct positioning on the frame) • Check that the engine oil cap has been inserted correctly • Check ground fastening on the engine • Check NEUTRAL cable fastening •...
Page 76 V7 III ABS Electrical system • Check that the coil in this position has the connector (wiring harness side) with two contacts TABLE C - CONDUIT • Check that the fall sensor arrow is up- wards and that the connector is grey •...
Page 77 V7 III ABS Electrical system Front side TABLE A - FRONT WHEEL ABS SENSOR PAS- SAGE 1. Front ABS sensor 2. Cable grommet • Pass the front ABS sensor wiring har- ness through the cable grommet as indicated. • Connect the front ABS sensor wiring harness with the brake pipe using cable guides (3) ELE SYS - 77...
Page 78 V7 III ABS Electrical system • Pass the ABS sensor wiring harness around the steering column and through the metallic cable grommet (4) on the frame TABLE B - STEERING LIGHTS CABLE PASSAGE ON THE HANDLE BAR • Using the cable guides (1), fasten the RH light switch wiring harness with the throttle cable •...
Page 79 V7 III ABS Electrical system TABLE B1 • Check that the front stop fastons are well fastened, by slightly pulling them TABLE C - INSTRUMENT CLUSTER 1. Cable grommet 2. Air temperature sensor 3. Connector support bracket 4. Connector support 5.
Page 80 V7 III ABS Electrical system TABLE C3 - INSTRUMENT CLUSTER (ANNI- VERSARIO/SPECIAL/RACER) 1. Medium sized clamp 2. Small clamp 3. Air temperature sensor TABLE C4 - INSTRUMENT CLUSTER (ANNI- VERSARIO/SPECIAL/RACER) • Once fully assembled, the instrument cluster appears as shown in the figure TABLE D - CABLE RUN ON THE STEERING HEADSTOCK 1.
Page 81 V7 III ABS Electrical system Central part TABLE A - CONDUIT ON THE FRAME • Check that the relays (1) are well in- serted • Fasten the rear part of the conduit us- ing a large clamp (2) TABLE A1 •...
Page 82: Table Of Contents
V7 III ABS Electrical system TABLE A2 • Main wiring harness (1) TABLE A3 • Right light switch connector (1) • Left light switch connectors (2) • Coil connector 2 (3) • Front ABS sensor connector (4) • USB socket connector (5) •...
Page 83 V7 III ABS Electrical system TABLE A6 • Pass t the PICK-UP connector (1) on the right side of the frame TABLE A7 • Check that the connector of the coil (1) is well coupled TABLE A8 • Check that the connector of the engine head temperature sensor (1) is well coupled •...
Page 84 V7 III ABS Electrical system TABLE B - COIL AND LEFT CYLINDER CON- NECTION • Check that the HV cable with grey mark (left engine head) is well inserted in the coil with grey mark on the connector TABLE C - COIL AND RIGHT CYLINDER CON- NECTION •...
Page 85 V7 III ABS Electrical system TABLE D2 • When the connector is fully inserted, the distance between the connector and the ABS control unit must be 7.5 mm (0.29 in) TABLE D3 • If the initial position of the connector and driving lever is not as the one shown in "TABLE D".
Page 86 V7 III ABS Electrical system TABLE E - LAMBDA PROBES PASSAGE UN- DER THE ENGINE 1. Right lambda probe wiring harness 2. Medium sized clamp 3. Left lambda probe connector 4. Cable grommet TABLE F - PICK UP CABLE PASSAGE •...
Page 87 V7 III ABS Electrical system TABLE F1 • Pass the pick up cable through the cen- tral flap, towards the right side of the motorcycle TABLE F2 • Pass the pick up cable to the back of the tank support and throttle cables TABLE F3 •...
Page 88 V7 III ABS Electrical system TABLE G - HORN AND REGULATOR 1. Voltage regulator 2. Horn • The regulator's cable must pass be- hind the frame bracket TABLE G1 • Check the connection of the flywheel white connector and regulator's black connector that must have a safety clamp to avoid disconnection.
Page 89 V7 III ABS Electrical system TABLE G2 • Using a medium clamp, fasten the reg- ulator's cables along the frame's tube TABLE H - FLYWHEEL CABLES PASSAGE • Using two medium clamps, fasten the flywheel's wiring harness ELE SYS - 89...
Page 90 V7 III ABS Electrical system TABLE I - NEUTRAL SENSOR CABLES PAS- SAGE • The wiring harness (1) of the neutral sensor must pass through the filter box support and in the cable guide (2) TABLE J - OIL PRESSURE and SECONDARY AIR SENSORS 1.
Page 91 V7 III ABS Electrical system TABLE K - INJECTORS • Check the correct connection of the in- jectors • The cable of the engine head temper- ature bulb (1) must pass under the rub- ber pipe TABLE L - CONNECTION OF THE LEFT LAMB- DA AND REAR ABS SENSOR •...
Page 92 V7 III ABS Electrical system TABLE L1 • The wiring harnesses of the rear ABS sensor, the connector of the side stand and the faston for the starter motor must pass through the cable grommet THE CONNECTOR OF THE LEFT LAMBDA PROBE AND THE ANTI-THEFT FITTING MUST NOT PASS THROUGH THE CABLE GROMMET •...
Page 93 V7 III ABS Electrical system TABLE N - RIGHT EXHAUST LAMBDA and REAR BRAKE CONNECTION 1. Check that the neutral sensor connector is well connected 2. Rear stop connector 3. Right Lambda probe connector TABLE N1 • Check that the right lambda probe con- nector is well connected and that it is hooked to the specific support ELE SYS - 93...
Page 94 V7 III ABS Electrical system TABLE N2 • The wiring harness of the lambda probe (1) must pass through the filter box and starter motor positive cable (2) TABLE O - REAR BRAKE WIRING HARNESS PASSAGE • Check that the rear brake sensor con- nector is well connected TABLE O1 •...
Page 95 V7 III ABS Electrical system TABLE O2 • Using a clamp, fasten the wiring har- ness of the rear brake sensor (1) to the wiring harness of the rear ABS sensor • The rear ABS sensor wiring harness must pass through the cable grommet TABLE O3 •...
Page 96 V7 III ABS Electrical system TABLE O4 • Fasten the wiring harness of the rear brake sensor (1) using the cable grom- mets (3) TABLE P - ENGINE BATTERY GROUND • An incorrect fastening of the fixing screws of the engine battery ground eyelet may cause the vehicle to catch fire •...
Page 97 V7 III ABS Electrical system TABLE Q2 • Pass the wiring harness of the side stand switch under the starter motor power supply cable TABLE Q3 • Pass the wiring harness of the side stand switch behind the MIU G3 control unit and check that the connector is well connected ELE SYS - 97...
Page 98: Main Wiring
V7 III ABS Electrical system TABLE R - ROUTING THE CABLES IN THE FIL- TER BOX/UNDER-SEAT AREA • The main wiring harness must pass under the central beam of the frame TABLE R1 • The layout of the main wiring harness and of the various branches in the filter box area must be as illustrated in the image...
Page 99 V7 III ABS Electrical system TABLE T - PASSAGE OF THE STARTER MO- TOR BATTERY • The cap of the battery positive (1) must be red • The cable that goes from the battery positive to the fuse box must be cov- ered with sheath (2) and the terminal must be covered with heath shrink ma- terial (3)
Page 100 V7 III ABS Electrical system TABLE T3 • Check that the faston is correctly in- serted TABLE T4 • The protection cap may remain outside for maximum 2-3 mm (0.078-0.118 in) Back side TABLE A - REAR MUDGUARD PRE-FITTING • Pre-fit the taillight wiring harness on the mudguard and fasten it to the spe- cific flaps on the mudguard...
Page 101 V7 III ABS Electrical system TABLE B - REAR ABS SENSOR PASSAGE 1. Cable fasteners • Secure the ABS sensor cable under the swingarm by means of the cable glands TABLE B1 - REAR ABS SENSOR PASSAGE • Route the wiring harness as indicated in figure, taking care not to pinch the speed sensor cable TABLE B2 - REAR ABS SENSOR PASSAGE...
Page 102 V7 III ABS Electrical system (STONE) ELE SYS - 102...
Page 103 V7 III ABS Electrical system Key: 1. Multiple connectors 2. Air temperature sensor 3. - 4. Instrument panel 5. Light relay 6. Starter motor relay ELE SYS - 103...
Page 104: Right Light Switch
V7 III ABS Electrical system 7. Clutch switch 8. Right light switch 9. Horn 10.Left light switch 11.Fall sensor 12.Rear stop switch 13.Front stop switch 14.Ignition switch 15.Rear right turn indicator 16.Parking - brake light 17.Taillight 18.Rear left turn indicator 19.Starter motor 20.Battery 21.Pull UP (resistance)
Page 105: Front Abs Sensor
V7 III ABS Electrical system 45.Front right turn indicator 46.ABS control unit 47.Front ABS sensor 48.Rear ABS sensor 49.ABS fuse 50.Secondary air system 51.Installation-ready for MGMP 52.USB socket (where applicable) 53.Pre-installation for anti-theft device 54.Antitheft device warning light 55.Jumper connector (without anti-theft device) Cable colour: Ar orange Az sky blue...
Page 106 V7 III ABS Electrical system Azzeramento icona manutenzione The system displays the function as follows: • when a maintenance interval threshold is exceeded, an icon with a spanner is shown on the LCD display. To reset Service proceed as follows: •...
Page 107 V7 III 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 108 V7 III 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 109 V7 III 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 110 V7 III ABS Electrical system Starter relay pin out 1. control unit relay output (blue/yellow) 2. Control unit ignition switched live (red/green) 3. Starter motor (violet) 4. / 5. Control unit ignition switched live (red/green) Diagnostic tool - Parameters and statuses •...
Page 111 V7 III ABS Electrical system Fuses FUSE DISTRIBUTION 1. Main fuse, coil 1 and 2, fuel pump, injectors 1 and 2, oxygen sensor 1 and 2, secondary air (30 A). 2. (Battery positive) MIU G3 ECU (5 A). 3. (Battery positive) Instrument panel, turn in- dicators, Blue Dash prewiring (5 A).
Page 112: Speed Sensor
V7 III ABS Electrical system 2. negative pole (black): ground lead Diagnostic tool - Parameters and statuses • Battery voltage - (V) - (Example value with key ON: 12.0 V, example value with engine on: 14.2 V) 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...
Page 113 V7 III ABS Electrical system • On the fork, left stanchion, near the brake calliper mounting bracket Pin-out 1. Ground (White) 2. Power supply voltage/Output signal (white/ brown) Diagnostic tool - Parameters and statuses • Vehicle speed - (km/h) • Front wheel speed - (km/h) Diagnostic tool - Electrical errors Electric malfunction 5D90...
Page 114 V7 III ABS Electrical system • Possible tone wheel fault due to deformations or dirt; the surface of the wheel bearings may be deteriorated. In very rare cases, abnormal tone wheel vibrations Troubleshooting • Check if the tone wheel is dirty, deformed or wrongly fixed If the tone wheel is not OK, replace it.
Page 115 V7 III ABS Electrical system REAR SPEED SENSOR Function To indicate the vehicle speed by reading the rear wheel turning speed Operation / Operating principle Magneto-resistive sensor: a square-wave pulse is generated with voltage approx. between 11.55 V and 11.25 V Level in electrical circuit diagram ABS system Position...
Page 116 V7 III ABS Electrical system • Connect to the ABS control unit diagnostics Diagnostics tool - Logic errors The signal works irregularly 5DA1 Error cause • Faulty sensor or signal interference Troubleshooting • Check speed sensor retainer; if not ok restore, if ok, check if the tone wheel is dirty, deformed or wrongly fixed;...
Page 117 V7 III ABS Electrical system • Faulty sensor or tone wheel, or tone wheel with wrong number of teeth or wrong tyre size Troubleshooting • Check that the speed sensor and the tone wheel are installed; If they are not, install them. If they are, check the speed sensor retainer;...
Page 118 V7 III ABS Electrical system • Target engine revs - (rpm) (Parameter valid at idle, setting depends especially on engine temperature: the ECU unit will try to keep the engine running at this revs, acting on the ignition advance) Diagnostic tool - Electrical errors Engine revolution sensor P0335 - open circuit Error cause •...
Page 119 V7 III ABS Electrical system • On the right head, towards the inside of the "V" of the engine • Connector: on the sensor Electrical specifications • Resistance at 0°C: 9.75 kΩ ± 5% • Resistance at 20°C: 3.747 kΩ ± 5% •...
Page 120 V7 III ABS Electrical system • Verify continuity of the wiring harness between the sensor connector and the control unit connector: Control unit PIN 13 - sensor PIN 2 and control unit PIN 15 - sensor PIN 1. If necessary, restore the wiring harness. •...
Page 121 V7 III ABS Electrical system 2. Negative signal sensor (green/white) 3. Heater ground (white/yellow) 4. Heater power (red/brown cable) Diagnostic tool - Parameters and statuses • Oxygen sensor voltage RH - (mV) • Right lambda probe - (---, Not enabled, Not active (start), Not active (heat.), Not active (rich), Operating, Not active (lean), Fault...
Page 122 V7 III ABS Electrical system • Check the sensor connector PIN 2 ground insulation. In the absence of insulation restore the wiring harness. • If PIN 1 and PIN 2 are insulated from the ground and the error persists, this means that there is a probable fault in the control unit.
Page 123 V7 III ABS Electrical system • Heater circuit: 12 -14 Ω at 20 °C (68 ° Pin-out 1. Positive sensor signal (pink) 2. Negative signal sensor (green/white) 3. Heater ground (violet/white) 4. Heater power (red/brown cable) Diagnostic tool - Parameters and statuses •...
Page 124 V7 III 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 wiring harness. • Check the sensor connector PIN 2 ground insulation. In the absence of insulation restore the wiring harness.
Page 125 V7 III ABS Electrical system Injector Function To supply the correct amount of petrol at the right timing Operation / Operating principle Injector coil is energised for the petrol passage to open RIGHT INJECTOR Level in electrical circuit diagram Coils and injectors Right injector position •...
Page 126 V7 III ABS Electrical system • Disconnect the right injector connector, turn the key to ON and activate the component through the diagnostic tool. • Verify the presence of voltage at the ends of the right injector connector; if there is no voltage, restore the wiring harness, otherwise proceed with the following checks.
Page 127: Fuel Pump
V7 III ABS Electrical system • Verify the absence of voltage at the left injector connector PIN 2; if present restore the wiring harness, otherwise proceed with the following checks. Short-circuit to negative: • Disconnect the left injector connector, turn the key to ON and activate the component through the diagnostic tool.
Page 128 V7 III ABS Electrical system 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. Diagnostic tool - Activation • Fuel pump Diagnostic tool - Electrical errors Fuel pump relay control P0230 - shorted to positive / shorted to negative / open circuit.
Page 129: Coil Connector
V7 III 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. LEFT COIL Level in electrical circuit diagram Coils and injectors Position •...
Page 130 V7 III ABS Electrical system • Verify the presence of voltage on the left coil connector PIN 1: if present, restore the wiring harness, otherwise replace the left coil. Open circuit: • Carry out the check procedure of the left coil and control unit connectors. •...
Page 131 V7 III ABS Electrical system • Short-circuit to positive: excessive voltage at PIN 8 of the control unit connector • Open circuit or short-circuit to negative: interruption of the circuit or zero voltage at PIN 8 of the control unit connector Troubleshooting Short-circuit to positive: •...
Page 132 V7 III ABS Electrical system Electrical specifications • Gear in neutral: closed circuit (0 V on wire from control unit to sensor / switch in continuity). • Gearshift engaged: open circuit (12 V on the wire from control unit to sensor) Pin-out: 1.
Page 133 V7 III ABS Electrical system Clutch lever sensor Function Indicates the clutch lever position to the control unit Operation / Operating principle In order to start the engine, pull the clutch also with the gear in neutral Level in electrical circuit diagram Start enable.
Page 134 V7 III ABS Electrical system • If present, check for continuity of the blue/green cable between the sensor and control unit PIN 15. • If absent, restore the wiring harness. The vehicle starts even without pulling the clutch lever Error cause •...
Page 135: Bank Angle Sensor
V7 III ABS Electrical system • Side stand - (Up, Down) Diagnosis The vehicle with clutch pulled, gear engaged and side stand retracted does not start (side stand switch always open) Error cause • Possible malfunction Troubleshooting • verify continuity of the grey/yellow cable between the sensor and PIN 19 of the control unit. •...
Page 136 V7 III ABS Electrical system 2. Ground (blue/green) 3. Power supply (grey/green) 4. Signal/consent (grey/sky blue) Diagnostic tool - Parameters and statuses • Tipping sensor - (Engine inhibited, Gear allowed, YES, Lean, Rich, Rich title, Error, Lean title) 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...
Page 137 V7 III ABS Electrical system 1. Power supply (red/brown) 2. Ground (black/white) Diagnostic tool - Parameters • Example value with key ON: 0 % • Example value with engine on: % Used only at 0 or 100% 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...
Page 138: Right Light Switch
V7 III ABS Electrical system there is voltage at PIN 1: if there is not voltage, check red/brown cable; if there is voltage, check component electrical characteristics and replace the component RUN/STOP switch Function Indicates the control unit if the rider wishes to en- able engine start-up or to keep the engine running Operation / Operating principle If the driver wants to shut off the engine or to dis-...
Page 139 V7 III ABS Electrical system wiring harness; if ok, check the red/yellow cable ground insulation (wiring harness side); If there is continuity with ground connection, restore the wiring harness; if it is OK, set the key to KEY OFF and check the engine control unit connector; if it is OK, replace the engine control unit Engine does not shut off with switch in "STOP"...
Page 140: Clutch Switch
V7 III ABS Electrical system Start up Start-up enabling switches Position • on the vehicle: under the tank, near the battery • connector: on the control unit from 34 Pin-out 1. Left coil control (1) 2. Right lambda probe heater signal (2) 3.
Page 141 V7 III ABS Electrical system 28./ 29.Engine revs positive signal (pick up) 30./ 31.Left lambda probe heater signal (1) 32.Right injector control (2) 33.Light logic relay control 34.Left injector control (1) Diagnostic tool - Control unit info screen page In this screen page are read the general data re- garding the control unit, for example: type of soft- ware, mapping, control unit programming data •...
Page 142 V7 III ABS Electrical system • Engine speed - (rpm) • Complete throt. angle - (°) • Engine temperature - (°C) • Intake air temperature - (°C) • Oxygen sensor voltage LH - (mV) • Oxygen sensor voltage RH - (mV) •...
Page 143 V7 III ABS Electrical system • Ctrl title cylinder RH - (Open Loop, Closed Loop) • Lean title cyl. RH - (NO, YES) • Rich title cyl. RH - (NO, YES) • Idle motor - (start ready, Open Loop, Closed Loop, delayed start, acceler- ated start, Minimum compensated, Stable out of min., Minimum, Acceler- ation, Deceleration, Cut-off, Restore...
Page 144: Fuel Pump
V7 III ABS Electrical system • Traction control (MGCT) - (Disabled, Enabled, Complete, Lean, Rich, Oper- ating) • Number of enabled keys - (.) • Previously unused Ecu - (NO, YES) • Start enabled - (NO, YES) • Previously unused Ecu-universal c. - (NO, YES) •...
Page 145 V7 III ABS Electrical system Diagnostic tool - Errors screen page This display shows potential errors detected in the vehicle (ATT) or stored in the control unit (MEM) and it allows to check error clearing (STO). Diagnostic tool - Adjustment This screen page is used to adjust some control unit parameters •...
Page 146 V7 III ABS Electrical system Error cause • The instrument panel does not indicate the presence of this error even in the ATT status Troubleshooting • Replace the engine control unit Error RAM P0604 - circuit not working Error cause •...
Page 147 V7 III ABS Electrical system • Once the throttle body or the injection control unit is replaced, it is necessary to connect to the diagnostic tool selecting FUEL INJECTION and carry out the operation "THROTTLE POSITIONER AUTODETECTION" Dashboard PIN: 1. CAN H line 2.
Page 148 V7 III ABS Electrical system • Occurs during the encoding of the first key connection, if the CAN line from the engine control unit is missing, the error is activated Identification • General alarm warning continuously on (red) and indication "ALARM DISCONNECTED" on the display Troubleshooting •...
Page 149 V7 III ABS Electrical system ENGINE OIL PRESSURE SENSOR Function Indicates the instrument panel if there is enough oil pressure 0.35 +/- 0.2 bar (5.1 +/- 2.9 PSI) in the engine. Operation / Operating principle Switch normally open. With oil pressure above 0.35 + / - 0.2 bar (5.1 + / - 2.9 PSI), closed circuit.
Page 150 V7 III ABS Electrical system connector PIN 3: if not OK, restore the wiring harness, if OK check continuity between the positive of the sensor and the vehicle ground, if not OK restore, if OK replace the sensor Error code B0002 (ALARM OIL PRESSURE) This alarm occurs when the engine is on and the pressure of the engine oil is low.
Page 151 V7 III ABS Electrical system 2. Ground (brown) Diagnosis An instrument panel temperature sensor failure is signalled when it is detected that the sensor circuit is open or shorted to positive/negative Error cause • Possible malfunction Troubleshooting • Check the sensor connector and the instrument panel connector (PIN 15); If they are not OK, restore.
Page 152 V7 III ABS Electrical system several sensors present on the motorbike has been obviated. The sensor signals are shared by the two electronic elaboration units (instrument panel and control unit). • Cable number reduction: The CAN line travels through a twisted cable to several nodes. •...
Page 153 V7 III ABS Electrical system • Check the engine control unit connector if not OK, restore; if OK, check the ground insulation of the two CAN lines from PIN 26 and PIN 27 of the engine control unit connector if not OK, restore wiring harness;...
Page 154 V7 III ABS Electrical system • Electric malfunction. Open circuit, short circuit to negative, short circuit to positive of one or both wires of CAN line Troubleshooting • Replace the wiring harness CAN line 5E16 - vehicle code message absent Error cause •...
Page 155 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 156 V7 III ABS Engine from vehicle HASSIS Pos. Description Type Quantity Torque Notes Screws fastening the tank support 25 Nm (18.44 lb ft) buffers to the frame Front cradle fixing screws 50 Nm (36.88 lb ft) Screw fastening the stand cross- 50 Nm (36.88 lb ft) Pre-permeated piece to the cradles...
Page 157 V7 III ABS Engine from vehicle Removing the engine from the vehicle • Remove the two fixing screws of the collector cover and remove the latter NOTE REPEAT THE OPERATION FOR THE RIGHT COVER AS WELL NOTE THE OPERATIONS FOR REMOVING THE EXHAUST TERMINAL, APPLY TO BOTH ENDS •...
Page 158 V7 III ABS Engine from vehicle • Loosen the clamp between the silencer and manifold • Remove the three fastening screws of the silencer to the support bracket • Slide and remove the silencer from the collector • Remove the two starter motor cover fixing screws ENG VE - 158...
Page 159 V7 III ABS Engine from vehicle • Remove the starter motor cover • Remove the clamps that secure the wiring harnesses of the Lambda proves • Disconnect the connectors of the lambda probes and free the wiring harness from the cable grommet ENG VE - 159...
Page 160 V7 III ABS Engine from vehicle • Remove the nuts and the correspond- ing fixing washers of the exhaust mani- folds • Remove the exhaust manifolds at the same time • Disconnect the clutch cable from the lever and free it from the cable grommet •...
Page 161 V7 III ABS Engine from vehicle • Disconnect the spark plugs tubes • Remove the screws fixing the manifold to the cylinder heads • Disconnect the engine oil pressure sensor connector • Remove the fixing nut of the engine ground cable ENG VE - 161...
Page 162 V7 III ABS Engine from vehicle • Remove the fixing nut of the power supply cable located on the starter mo- tor. Then remove the cable • Disconnect the starter motor faston • Remove the two starter motor fixing screws •...
Page 163 V7 III ABS Engine from vehicle • Disconnect the secondary air system pipes from the cylinder heads • Remove the tone wheel sensor • Remove the clamps fixing the flywheel wiring harness to the brake pipes • Disconnect the flywheel/alternator connector and free it from the passage in the frame ENG VE - 163...
Page 164 V7 III ABS Engine from vehicle • Remove the fixing screws of the right rider footrest • Remove the front screws fixing the cra- dle, making sure to recover the nuts and washers • Remove the lower fixing pin of the cra- dle making sure to collect the washer and the nut •...
Page 165 V7 III ABS Engine from vehicle • Remove the lower fixing screws of the rear shock absorbers and move them from the support pins on the swing- arm//bevel gear • Remove the rear brake calliper and the ABS sensor • Remove the cable grommet plate placed under the swingarm •...
Page 166 V7 III ABS Engine from vehicle • Slightly lift the frame and disconnect the blow-by pipe • Lift the frame sufficiently and remove the engine complete with swingarm ENG VE - 166...
Page 167 INDEX OF TOPICS NGINE...
Page 168 V7 III ABS Engine TO CONSULT THE CHAPTER ABOUT THE ENGINE AND ITS COMPONENTS PLEASE REFER TO THE APPROPRIATE MANUAL: "MSS Engine 750 Euro 4" ENG - 168...
Page 169 INDEX OF TOPICS P SUPP OWER SUPPLY...
Page 170 V7 III ABS Power supply Circuit diagram key: 1. Fuel tank 2. Fuel pump 3. Canister 4. Throttle body 5. Fuel delivery pipes 6. Fuel vapour recovery pipe 7. Check valve 8. Breather pipe Injection P SUPP - 170...
Page 171 V7 III 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 P SUPP - 171...
Page 172 V7 III ABS Power supply 13.Side stand switch 14.Gear sensor 15.Fall sensor P SUPP - 172...
Page 173 INDEX OF TOPICS SUSP USPENSIONS...
Page 174 V7 III ABS Suspensions Handlebar ANDLEBAR AND ONTROLS Pos. Description Type Quantity Torque Notes Screw fixing handlebar support U-bolts to 50 Nm (36.88 lb ft) steering plate Handlebar U-bolt fastener screws 25 Nm (18.44 lb ft) Mirror fixing Manual Light switch fastening screws SWP 5 1.5 Nm (1.11 lb ft) Throttle cable cover fastening screws...
Page 175 V7 III 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) Loctite 243 Screw fastening the clutch control U-bolt to 10 Nm (7.38 lb ft)
Page 176 V7 III ABS Suspensions • Remove the light switches • Unscrew and remove the four fasten- ing screws (1) • Retrieve the two upper U-bolts (2) • Remove the handlebar (3) (RACER) • Remove the upper steering yoke • Remove the light switches •...
Page 177 V7 III ABS Suspensions • Remove the left-hand semi-handlebar SUSP - 177...
Page 178: Front Fork
V7 III ABS Suspensions Front fork RONT SUSPENSION TEERING Pos. Description Type Quantity Torque Notes Screws fastening stanchion on upper plate M8x35 25 Nm (18.44 lb ft) Steering head fastening bushing 100 Nm (73.76 lb ft) Steering headstock lock nut 50 Nm (36.88 lb ft) Pre-torque 60 Nm (44.25 lb ft) Headstock counter-lock ring...
Page 179 V7 III ABS Suspensions Pos. Description Type Quantity Torque Notes Connector plate fastening screw M6x16 10 Nm (7.38 lb ft) Screws fastening stanchion on lower plate 45 Nm (33.19 lb ft) Pumping unit fastening screw 50 Nm (36.88 lb ft) Diagram Key: 1.
Page 180: Removing The Fork Legs
V7 III ABS Suspensions 17.Complete cap 18.O-ring Removing the fork legs The following procedure is only shown from one side of the vehicle, but is valid for both stan- chions CAUTION DURING THE OPERATIONS DESCRIBED BELOW, THE STANCHIONS AND THEIR INTERNAL COMPONENTS SHOULD BE TIGHTENED ON A VICE.
Page 181 V7 III 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 182 V7 III 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 183 V7 III 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 wheel holder fork leg together with the sealing ring, the cap, the upper bush- ing and lower bushings.
Page 184 V7 III 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 185 V7 III 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 186 V7 III 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 187 V7 III 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. SUSP - 187...
Page 188 V7 III ABS Suspensions Steering bearing RONT SUSPENSION TEERING Pos. Description Type Quantity Torque Notes Screws fastening stanchion on upper plate M8x35 25 Nm (18.44 lb ft) Steering head fastening bushing 100 Nm (73.76 lb ft) Steering headstock lock nut 50 Nm (36.88 lb ft) Pre-torque 60 Nm (44.25 lb ft) Headstock counter-lock ring...
Page 189 V7 III ABS Suspensions Pos. Description Type Quantity Torque Notes Connector plate fastening screw M6x16 10 Nm (7.38 lb ft) Screws fastening stanchion on lower plate 45 Nm (33.19 lb ft) Pumping unit fastening screw 50 Nm (36.88 lb ft) Adjusting play •...
Page 190 V7 III ABS Suspensions • Unscrew the lower ring nut in order to repeat the steering play adjustment procedure correctly. • Pre-tighten the lower ring nut to the torque of 60 Nm (44.25 lb ft). • Steer repeatedly completely left and completely right to allow the bearings to settle. •...
Page 191 V7 III ABS Suspensions Shock absorbers EAR SHOCK ABSORBERS Pos. Description Type Quantity Torque Notes Top rear shock absorber fixing screws 10 Nm (7.38 lb ft) Pre-permeated Pin fastening left shock absorber to the swing- 35 Nm (25.81 lb ft) Pin fastening the shock absorber to gearbox 35 Nm (25.81 lb ft) Screw fastening right shock absorber to pin...
Page 192 V7 III ABS Suspensions Removing (SPECIAL/STONE/ANNIVERSARIO) • Remove the silencers RH REAR SHOCK ABSORBER • Unscrew and remove the two screws • Retrieve the two bushings (2) • Remove the RH rear shock absorber LH REAR SHOCK ABSORBER • Undo and remove the screw (1) and retrieve the bushing (2) •...
Page 193 V7 III ABS Suspensions • Remove the rear shock absorber (6) (RACER) • Remove the silencers REAR LEFT SHOCK ABSORBER • Undo and remove the screw (1) • Retrieve the bushing (2) • Holding the pin (3) in place, unscrew and remove the nut (4) •...
Page 194 V7 III ABS Suspensions REAR RIGHT SHOCK ABSORBER • Undo and remove the fastening screw • Retrieve the bushing (2) • Undo and remove the fastening screw • Retrieve the bushing (4) • Removal of right rear shock absorber SUSP - 194...
Page 195 INDEX OF TOPICS CHAS HASSIS...
Page 196: Front Wheel
V7 III ABS Chassis Wheels Front wheel RONT WHEEL Pos. Description Type Quantity Torque Notes Wheel axle 80 Nm (59.00 lb ft) Front brake disc fixing screws 25 Nm (18.44 lb ft) Loctite 243 ABS-sensor fixing stud bolt 6 Nm (4.43 lb ft) Pre-permeated Cable gland nut 6 Nm (4.43 lb ft)
Page 197 V7 III 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 198: Rear Wheel
V7 III 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 brake disc fastening screws 25 Nm (18.44 lb ft) Loctite 243 Rear wheel axle fastener pin + nut 120 Nm (88.51 lb ft)
Page 199 V7 III ABS Chassis Rimozione • 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 200 V7 III 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 THAT THE PROTECTION CASING OF THE CARDAN COULD BE DAMAGED CHAS - 200...
Page 201 V7 III ABS Chassis • Working from the LH side, remove the LH 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 202 V7 III ABS Chassis - 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). • Repeat the operation for all spokes by proceeding in successive order; •...
Page 203 V7 III ABS Chassis Removing • Remove the silencers • Remove the fixing nut of the cable grommet plate and disconnect it from the swingarm • Remove the ABS sensor and the brake calliper • Unscrew and remove the fixing screw of the calliper holder.
Page 204 V7 III ABS Chassis • Remove the screw fixing the right-hand rear right shock absorber and pull it from the pin on the drive shaft • Unscrew and remove the nut and col- lect the washer. • Loosen the wheel pin locking screw. •...
Page 205 V7 III ABS Chassis • 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 • Unscrew the nuts. •...
Page 206 V7 III ABS Chassis • 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; otherwise, replace the joint. •...
Page 207 V7 III ABS Chassis Removing • Undo the four nuts and collect the washers. • Slide off the gearcase together with the swingarm. • Slide off the sleeve from the pinion. • Slide off the spring. • Slide off the sealing ring. •...
Page 208 V7 III ABS Chassis • 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. • Insert the grooved shank of the pinion on the tool and unscrew the nut.
Page 209 V7 III ABS Chassis • Slide off the shim adjustment washer. • Slide off the O-ring. • Slide off the oil seal. • Slide of the tapered bearing from the case. • Slide off the O-ring. • Slide off the spacer. •...
Page 210 V7 III ABS Chassis • Check that both tapered bearings are not damaged, that the rollers are not damaged or worn; otherwise, replace them. • Check that the adjustment washers are not deformed or broken; otherwise, replace them. • Check that the sealing rings are not shattered, spoiled or worn; otherwise, replace them. Montaggio •...
Page 211 V7 III ABS Chassis • Fit the adjustment shim washer. • Fit the internal ring of the bearing on the pinion using the suitable punch (19926200). • Fit both shim washers on the pinion. • Fit the spacer on the pinion. •...
Page 212 V7 III ABS Chassis • Fit the oil seal. • Fit the O-ring. • Fit the spacer. • Insert the grooved shank of the pinion on the tool (19907100) and tighten the nut. Smontaggio gruppo scatola • Undo the screws and collect the wash- ers.
Page 213 V7 III ABS Chassis • 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. • Slide off the gaskets. • Slide off the shimming ring. •...
Page 214 V7 III ABS Chassis • Remove the conical crown. • Slide off the drilled bolt from the bear- ing. • Remove the sealing ring. • 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 215 V7 III ABS Chassis • Remove the external ring of the needle bearing from the housing using the suitable extractor (19927500). • Remove the sealing ring and the wash- Controllo • Check that the drilled bolt tongues, where the anti-vibration rubbers operate, are not spoiled; that the surfaces of: the sealing ring;...
Page 216 V7 III ABS Chassis For coupling, proceed as follows: • Provisionally lock the complete pinion case on the housing with two nuts and appropriate spacers. • Fit the corresponding tool on the crown (19928800). • Insert the tool on the bearing cage in the housing.
Page 217 V7 III ABS Chassis • Fit the drilled bolt-crown unit cover and their spacers and gaskets on the hous- ing and provisionally tighten the screws. • On the crown holder drilled bolt, fit a "Universal" extractor that with appro- priate central spacers slightly presses the crown towards the brake disc side.
Page 218 V7 III ABS Chassis • If the contact is like this, the crown is too near the pinion rotation axis: de- tach the crown by increasing spacer thickness. • If the contact is like this, the pinion is too near the rotation axis of the crown: detach the pinion by reducing spacer thickness •...
Page 219 V7 III ABS Chassis • Fit the washer on the gearcase. • Fit the sealing ring on the housing us- ing the suitable punch (19926000). • Fit the external ring of the needle bear- ing on the housing using the suitable punch (19926500).
Page 220 V7 III ABS Chassis • 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. • Fit the drilled bolt on the cover. •...
Page 221 V7 III ABS Chassis • Fit the plates and tighten the screws. • Insert the washer. • Insert the washer. • Fit the O-ring. • Insert the gaskets and the shimming ring on the cover. • Tighten the screws with plates and washers.
Page 222 V7 III ABS Chassis • Fit the braking disc on the drilled bolt by locking the screws with the washers using a torque wrench. • When refitting the bevel pinion case on the transmission, bear in mind that the oil passage grooves with holes should be fitted vertically (observing the grooves, one should be facing up- wards and the other facing the ground).
Page 223 V7 III ABS Chassis • Correctly insert the stud bolts of the gearcase in the holes of the swingarm . • Screw the nuts with the washers with- out locking them. CHAS - 223...
Page 224 V7 III ABS Chassis Exhaust XHAUST SYSTEM Pos. Description Type Quantity Torque Notes Lambda probes fastener 38 Nm (28.03 lb ft) Screws fastening heat shields to 8 Nm (5.90 lb ft) Pre-permeated manifolds Screws fastening heat shields to si- 8 Nm (5.90 lb ft) Pre-permeated lencers Screws fastening silencers to frame...
Page 225 V7 III ABS Chassis Key: 1. Right exhaust manifold 2. Left exhaust manifold 3. Lambda probe 4. Lambda probe 5. Left manifold protection 6. Right manifold protection 7. Exhaust gasket 8. Nut 9. Washer 10.Clamp 11.Screw 12.Washer 13.Elastic spacer 14.Screw 15.Washer 16.Elastic plate 17.Clamp...
Page 226 V7 III ABS Chassis 22.Left silencer support bracket 23.Screw 24.Bushing 25.Spacer 26.Rubber ring 27.Nut 28.Screw 29.Washer 30.Right silencer protection 31.Left silencer protection 32.Thermal cover 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.
Page 227 V7 III ABS Chassis • Remove the silencer protection • Remove the three fastening screws of the silencer to the support bracket • Loosen the clamp between the silencer and manifold • Slide and remove the silencer from the collector NOTE THE OPERATIONS FOR REMOVING THE EXHAUST TERMINAL, APPLY TO BOTH ENDS CHAS - 227...
Page 228 V7 III ABS Chassis Removing the exhaust manifold • Remove the fixing nuts (1) of the ex- haust manifold paying attention to keep the washers (2) • Scollegare i connettori delle sonde lambda e liberare i cablaggi dai pas- saggi cavi/fascette •...
Page 229 V7 III ABS Chassis • Remove the ring nuts • Disconnect the left lambda probe con- nector • 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 CHAS - 229...
Page 230 V7 III ABS Chassis • Loosen the clamps between the joint and the exhaust manifolds • Remove the manifolds Removing the lambda sensor • Remove the starter motor • Disconnect the left lambda probe con- nector (1) • Disconnect the right Lambda probe connector (2) •...
Page 231 V7 III ABS Chassis • Unscrew and remove the two lambda probes. Aria secondaria Tightening torque ECONDARY AIR SYSTEM Pos. Description Type Quantity Torque Notes Red valve cover fixing SHC screws M5x16 3-4 Nm (2.21-2.95 lb ft) CHAS - 231...
Page 232 V7 III ABS Chassis key: 1. Air filter casing 2. Secondary air valve 3. Secondary air system pipe 4. Secondary air system inlets on the engine • Two auxiliary air inlets have been included in the cylinder head which, in combination with the injection system with oxygen sensor and three-way catalytic converter, ensure compli- ance with severe new Euro 4 emissions regulations CHAS - 232...
Page 233 V7 III ABS Chassis • Undo the screws fastening the reed valve cover. • Remove the reed valve cover • Remove the reed valve. • Remove the flame trap. CHAS - 233...
Page 234 V7 III ABS Chassis • A valve controlled by the engine ECU is installed under the tank, which al- lows air to flow towards the cylinders via two flexible hoses. • This valve is connected directly to the filter box via a flexible hose. Sistema evaporativo canister key: 1.
Page 235 V7 III ABS Chassis • The canister is installed with the intake inlet above the tank inlet • Check the correct passage of the pipes on the chassis CHAS - 235...
Page 236 V7 III ABS Chassis • Check the correct passage of the pipes on the starter motor CHAS - 236...
Page 237 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 238 V7 III ABS Braking system SYSTEM Pos. Description Type Quantity Torque Notes Control unit bracket fastening to the M6x16 10 Nm (7.38 lb ft) frame Screw fastening brake lines fasten- 3 Nm (2.21 lb ft) ing plates Clamp fastening screw 6 Nm (4.43 lb ft) BRAK SYS - 238...
Page 239 V7 III ABS Braking system Key: 1. ABS control unit 2. Front ABS sensor 3. Rear ABS sensor 4. Battery 5. Injection loads relay 6. ECU 7. Instrument panel 8. K line (diagnosis) 9. Ignition switch 10.Fuses 11.Right light switch 12.Light switch left ABS control unit pin out 1.
Page 240 V7 III ABS Braking system Foreword Key: 1. ABS control unit 2. ABS control unit front pump pipe 3. ABS control unit front calliper pipe 4. ABS control unit rear calliper pipe 5. ABS control unit rear pump pipe 6. Washer 7.
Page 241 V7 III ABS Braking system 20.Ring 21.Cable guide 22.Clip Operating diagram ABS functional diagram key BRAK SYS - 241...
Page 242 V7 III ABS Braking system 1. Front system circuit 2. Front brake pump 3. Front brake lever 4. Rear system circuit 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)
Page 243 V7 III ABS Braking system C - Pressure maintained: the pressure in the callipers (8-9) remains low until total recovery of speed / wheel grip. The system restores the fluid taken from the calliper (8-9) in the section of the system between the brake pump (2-5) and the ABS inlet valve (10-12).
Page 244 V7 III ABS Braking system • The ABS system intervenes by releasing pressure from the calliper until the wheel turns again at the same speed of the other wheel. It is not possible to brake for an instant. • if the speed difference lasts long, the system may detect an error and deactivate the ABS system.
Page 245 V7 III ABS Braking system • the ABS warning light turns on permanently The ABS system is deactivated! The system operates perfectly just as any other braking system without ABS. The detection of malfunctions may require more or less time according to the type of failure. Error detection logic foresees that for the errors to be diagnosed one or more conditions must persist within a given time.
Page 246 V7 III ABS Braking system Use of diagnostics instrument for ABS system Abs screen pages ECU INFO screen page Diagnostic tool - Control unit info screen page In this screen page are read the general data re- garding the control unit, for example: type of soft- ware, mapping, control unit programming data •...
Page 247 V7 III ABS Braking system Quality test of the sensors When turning the wheel or acting on the brake, a variation of parameters must be detected. ACTIVATION screen page On this screen page, you can delete the errors from the memory of the controller and you can en- able some systems controlled by the control unit.
Page 248 V7 III ABS Braking system ERRORS screen page This display shows potential errors detected in the vehicle (ATT) or stored in the control unit (MEM) and it allows to check error clearing (STO). ERRORS Diagnostic tool characteristics Notes Front wheel speed sensor: Electric malfunction 5D90 Electrically defective wiring or sensor Front wheel speed sensor: The signal changes irregularly Faulty sensor;...
Page 249 V7 III ABS Braking system Diagnostic tool report diagnostic tool In the following are described the procedure to be performed through the diagnostic tool in order to generate an errors report: • When started the program, select the brand. • Select the vehicle and the component.
Page 250 V7 III ABS Braking system • 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. • If there is no PDF printer, there are several free programs, ask the infor- mation systems to install it.
Page 251 V7 III ABS Braking system Modulator Before removing the modulator, it is necessary to completely purge the braking system. MODULATOR REMOVAL • Remove the horn. • Disconnect the connector (1). • With a felt-tip pen, mark a reference on the pipes and on the ABS control unit to avoid inverting them when refitting •...
Page 252 V7 III ABS Braking system • Operating from the left side of the mo- torcycle, remove the ABS modulator • To remove the ABS modulator from the support, remove the three fixing screws Rear brake calliper EAR BRAKE CALLIPER Pos. Description Type Quantity...
Page 253 V7 III ABS Braking system Key: 1. Rear brake calliper 2. Spacer 3. Brake calliper mounting plate 4. Bushing 5. Screw 6. Bleed + cap 7. Pins + spring kit 8. Brake pads copy Removal • Obtain a special container and empty the system •...
Page 254 V7 III ABS Braking system • Remove the two calliper fixing screws • Remove the calliper Front brake calliper RONT BRAKE CALLIPER Pos. Description Type Quantity Torque Notes Front brake calliper fixing screws 50 Nm (36.88 lb ft) BRAK SYS - 254...
Page 255 V7 III ABS Braking system Key: 1. Front left brake calliper 2. Screw 3. Bleed + cap 4. Spring 5. Pins + calliper springs 6. Pair of pads Removal • Obtain a special container and empty the system • Remove the screw fixing the brake pipe to the clamp BRAK SYS - 255...
Page 256 V7 III ABS Braking system • Remove the two calliper fixing screws • Remove the calliper Rear brake disc EAR WHEEL Pos. Description Type Quantity Torque Notes Rear brake disc fastening screws 25 Nm (18.44 lb ft) Loctite 243 Rear wheel axle fastener pin + nut 120 Nm (88.51 lb ft) Rear ABS sensor fastening screw 6 Nm (4.43 lb ft)
Page 257 V7 III 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 258 V7 III ABS Braking system THE BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE SPECI- FICATIONS OF THE 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.
Page 259 V7 III 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 260: Front Brake Pads
V7 III 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 261: Rear Brake Pads
V7 III 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 - 261...
Page 262 V7 III 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. The presence of air is signalled by the "sponginess"...
Page 263 V7 III 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 264 V7 III 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 265 V7 III ABS Braking system Front brake pump RONT BRAKE MASTER CYLINDER Pos. Description Type Quantity Torque Notes Front brake master cylinder U-bolt fixing 10 Nm (7.38 lb ft) screws Brake light switch fastening screws 3 Nm (2.21 lb ft) Removal •...
Page 266 V7 III 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 MASTER CYLINDER Pos.
Page 267 V7 III ABS Braking system Pos. Description Type Quantity Torque Notes Rear brake lever peg fastening 20 Nm (14.75 lb ft) Loctite 243 Rear brake lever fixing pin 20 Nm (14.75 lb ft) Fork fixing nut 10 Nm (7.38 lb ft) IDER FOOTREST EAR BRAKE LEVER Pos.
Page 268 V7 III ABS Braking system • Remove the two brake pump rear fixing screws at the support plate • Move the O-Ring from the retainer plate and remove it • Remove the brake pump (RACER) • Drain off the rear brake system •...
Page 269 V7 III 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 BUBBLES IN THE SYSTEM BRAK SYS - 269...
Page 270 INDEX OF TOPICS BODYW ODYWORK...
Page 271 V7 III ABS Bodywork EAR LIGHT UNIT Pos. Description Type Quantity Torque Notes Screws fastening taillight support to the mud- 4 Nm (2.95 lb ft) guard Rear turn indicator fastener nut 6 Nm (4.43 lb ft) Reflector fixing nut retainer to the support 4 Nm (2.95 lb ft) Screw fastening license plate mounting on SWP 5...
Page 272 V7 III ABS Bodywork EAR MUDGUARD Pos. Description Type Quantity Torque Notes Rear mudguard fixing screws 20 Nm (14.75 lb ft) Front and centre fastening screw rear mud- 10 Nm (7.38 lb ft) guard Rear splash guard fastening screws 10 Nm (7.38 lb ft) OCK KIT Pos.
Page 273 V7 III ABS Bodywork ENTRAL BODYWORK Pos. Description Type Quantity Torque Notes Starter motor cover fastening screws 4 Nm (2.95 lb ft) Throttle body cover fastening screws 3 Nm (2.21 lb ft) Side panel fastening screws 4 Nm (2.95 lb ft) BODYW - 273...
Page 274 V7 III ABS Bodywork ILTER BOX Pos. Description Type Quantity Torque Notes Filter box fastening screws SWP M5 3 Nm (2.21 lb ft) Air filter cover fastening screws SWP M5 3 Nm (2.21 lb ft) Filter casing/frame fastening screw SWP M5 3 Nm (2.21 lb ft) BODYW - 274...
Page 275 V7 III ABS Bodywork UEL TANK Pos. Description Type Quantity Torque Notes Screws fastening fuel pump to fuel tank 5 Nm (3.69 lb ft) Pre-permeated Rear tank fastening screw 25 Nm (18.44 lb ft) RONT MUDGUARD Pos. Description Type Quantity Torque Notes Screws fastening the stabiliser plate to the fork...
Page 276 V7 III ABS Bodywork Pos. Description Type Quantity Torque Notes Screw fastening the mudguard to the stabiliser 10 Nm (7.38 lb ft) Loctite 243 plate RONT LIGHTS Pos. Description Type Quantity Torque Notes Headlamp fastening screws 15 Nm (11.10 lb ft) Front turn indicators fastening screws 5 Nm (3.69 lb ft) Screws fastening the headlight support strips...
Page 277 V7 III ABS Bodywork RONT LIGHTS Pos. Description Type Quantity Torque Notes Headlamp fastening screws M8x45 15 Nm (11.06 lb ft) Front turn indicators SHC fastening screws M6x25 10 Nm (7.38 lb ft) Viti TCEI fissaggio braccialetti supporto fanale M6x25 10 Nm (7.38 lbf ft) •...
Page 278 V7 III ABS Bodywork • Disconnect the connector from the headlamp and remove it BULB REPLACEMENT • To replace the bulbs, remove the com- plete parabole from the headlight body by undoing the screw (1) LOW BEAM / HIGH BEAM LIGHT BULB •...
Page 279 V7 III ABS Bodywork Headlight fairing (RACER) REMOVAL OF THE TOP FAIRING • Unscrew and remove the two screws • Remove the top fairing (2) • Retrieve the two washers (3) BODYW - 279...
Page 280 V7 III ABS Bodywork • Retrieve the two fastening nuts (4) • Undo and remove the fastening screw • Retrieve the bushing (6) • Undo and remove the fastening screw • Remove the right-hand top fairing sup- port bracket (8) BODYW - 280...
Page 281 V7 III ABS Bodywork • Undo and remove the fastening screw • Retrieve the bushing (10) • Undo and remove the fastening screw (11) • Remove the left-hand top fairing sup- port bracket (12) Disassembling the lock • Remove the LH side fairing •...
Page 282 V7 III ABS Bodywork • Remove the fork spring (2) • Remove the cable support plate (3) • Remove the ignition switch assembly BODYW - 282...
Page 283 V7 III ABS Bodywork Taillight assy. EAR LIGHT UNIT Pos. Description Type Quantity Torque Notes Screws fastening taillight support to the mud- 4 Nm (2.95 lb ft) guard Rear turn indicator fastener nut 6 Nm (4.43 lb ft) Reflector fixing nut retainer to the support 4 Nm (2.95 lb ft) Screw fastening license plate mounting on SWP 5...
Page 284 V7 III ABS Bodywork • Detach the wiring harness from the point indicated in figure • Extract and remove the wiring connec- tor from the point indicated in figure • Extract the wiring from the point indi- cated in figure •...
Page 285 V7 III ABS Bodywork REMOVAL OF THE RIGHT-HAND RIDER FOOTREST SUPPORT • Remove the gasket (1) • Unhook and remove the clip (2) • Holding the nut in place as illustrated in the figure, unscrew and remove the two rear brake master cylinder fasten- ing screws (3) •...
Page 286 V7 III ABS Bodywork • Remove the microswitch (5) turning the footrest support in order not to damage the microswitch cabling • Remove the right-hand rider footrest support (6) REMOVAL OF THE REAR BRAKE LEVER • Remove the right-hand rider footrest support •...
Page 287 V7 III ABS Bodywork • Remove the rear brake lever (4) • Retrieve the O-ring (5) REMOVAL OF THE RIGHT-HAND RIDER FOOTREST • Remove the snap ring(1) • Remove the pin (2) • Remove the right-hand rider footrest • Retrieve the spring (4) BODYW - 287...
Page 288 V7 III ABS Bodywork • Remove the clip (1) • Remove the gear shift lever tie-rod (2) from the ball joint • Undo and remove the two fastening screws (3) • Remove the left-hand rider footrest support (4) BODYW - 288...
Page 289 V7 III ABS Bodywork REMOVAL OF THE GEAR SHIFT LEVER • Remove the right-hand rider footrest • Holding the nut in place as illustrated in the figure, undo and remove the fas- tening screw (1) • Remove the gear shift lever (2) •...
Page 290 V7 III ABS Bodywork • Remove the pin (2) • Remove the left-hand rider footrest (3) • Retrieve the spring (4) REMOVAL OF THE PASSENGER FOOTRESTS SUPPORT • Undo and remove the two fastening screws (1) • Holding the nut in place as illustrated in the figure, undo and remove the screw •...
Page 291 V7 III ABS Bodywork REMOVAL OF THE PASSENGER FOOTREST • Remove the snap ring(1) • Remove the pin (2) • Remove the right-hand passenger footrest (3) • Retrieve the two plates (3), the ball (4) and the spring (5) • Repeat the entire operation to remove the left-hand passenger footrest (RACER)
Page 292 V7 III ABS Bodywork • Remove the two spacers (3) • Unscrew and remove the two screws • Remove the right-hand rider footrest support (5) REMOVAL OF THE RIGHT-HAND RIDER FOOTREST • Remove the clip (1) • Retrieve the washer (2) BODYW - 292...
Page 293 V7 III ABS Bodywork • Remove the pin (3) • Remove the right-hand rider footrest • Retrieve the spring (5) REMOVAL OF REAR BRAKE LEVER • Remove the lever return spring (1) CAUTION DISASSEMBLE THE BRAKE LEVER RETURN SPRING FROM THE FOOTREST SUPPORT, TAKING CARE NOT TO WEAKEN IT.
Page 294 V7 III ABS Bodywork • Retrieve the two O-rings (4) • Retrieve the right-hand rider footrest REMOVAL OF THE LEFT-HAND RIDER FOOT- REST SUPPORT • Remove the clip (1) • Disconnect the gear shift lever tie-rod (2) from the ball joint •...
Page 295 V7 III ABS Bodywork • Remove the footrest support (4) REMOVAL OF THE GEAR SHIFT LEVER • Undo and remove the fastening screw • Removal of the gear shift lever (2) REMOVAL OF THE LEFT-HAND RIDER FOOT- REST • Remove the clip (1) BODYW - 295...
Page 296 V7 III ABS Bodywork • Retrieve the washer (2) • Remove the pin (3) • Remove the left-hand rider footrest (4) • Retrieve the spring (5) REMOVAL OF THE PASSENGER FOOTREST SUPPORT • Carry out the footrest removal proce- dure •...
Page 297 V7 III ABS Bodywork • Remove the support (2) • Remove the heel guard (3) • Holding the nut in place as illustrated in the figure, undo and remove the screw • Retrieve the bushing (5) • Retrieve the washer (6) and the nut (7) BODYW - 297...
Page 298 V7 III ABS Bodywork • Unscrew and remove the two screws • Remove the support (9) • Remove the support (10) • Repeat the entire procedure to remove the left-hand passenger footrest sup- port REMOVAL OF THE PASSENGER FOOTREST • Remove the snap ring(1) •...
Page 299 V7 III ABS Bodywork • Remove the right-hand passenger footrest (3) • Retrieve the two plates (4), the spring (5) and the ball (6) • Repeat the entire operation to remove the left-hand passenger footrest Side body panels BODYW - 299...
Page 300 V7 III ABS Bodywork ENTRAL BODYWORK Pos. Description Type Quantity Torque Notes Starter motor cover fastening screws 4 Nm (2.95 lb ft) Throttle body cover fastening screws 3 Nm (2.21 lb ft) Side panel fastening screws 4 Nm (2.95 lb ft) (SPECIAL/STONE/ANNIVERSARIO) •...
Page 301 V7 III ABS Bodywork • Undo and remove the three fastening screws (1) • Remove the right side fairing panel (2) • To remove the left side fairing, the op- eration described above must be re- peated and the saddle opening cable must be unhooked from the ignition switch assembly Air box...
Page 302 V7 III ABS Bodywork • Remove the four fastening screws (3) of the air filter cover • Remove the air filter cover (4) and the filter (5) • Remove the two screws securing the fuse box support and move it to have greater freedom of movement for sub- sequent operations •...
Page 303 V7 III ABS Bodywork • Remove the clamp present in the col- lector that blocks the filter case to the throttle body • Remove the two bottom fastening nuts of the splash guard • Operating on the left side of the motorcycle, remove the blow-by pipe (6) from the filter case, while the right side, remove the secondary air pipe (7) •...
Page 304 V7 III ABS Bodywork • Pull the filter case from the right side of the motorcycle • Remove the collector from the filter case • Remove the locking screws from the filter case • Remove the cover (8) and the blow-by filter (9) BODYW - 304...
Page 305 V7 III ABS Bodywork • Check and replace the two seals present in the cover Rear mudguard EAR MUDGUARD Pos. Description Type Quantity Torque Notes Rear mudguard fixing screws 20 Nm (14.75 lb ft) Front and centre fastening screw rear mud- 10 Nm (7.38 lb ft) guard Rear splash guard fastening screws...
Page 306 V7 III ABS Bodywork • Remove the saddle • Unscrew and remove the two screws • Unscrew and remove the two fixing screws (2) from both sides of the vehi- • Retrieve the two washers (3) • Undo and remove the screw (4) •...
Page 307 V7 III ABS Bodywork • Remove the saddle opening cable from the points indicated in figure • Remove the rear mudguard (6) com- plete with the rear light cluster • Remove the two bushings (7) • Unscrew and remove the three screws BODYW - 307...
Page 308 V7 III ABS Bodywork • Remove the strengthener (9) • Remove the rear light cluster Splash guard EAR MUDGUARD Pos. Description Type Quantity Torque Notes Rear mudguard fixing screws 20 Nm (14.75 lb ft) Front and centre fastening screw rear mud- 10 Nm (7.38 lb ft) guard Rear splash guard fastening screws...
Page 309 V7 III ABS Bodywork • Remove the rear mudguard • Remove the two lower nuts • Remove the two upper screws com- plete with self-locking nuts • Remove the splash guard BODYW - 309...
Page 310: Fuel Tank
V7 III ABS Bodywork Fuel tank UEL TANK Pos. Description Type Quantity Torque Notes Screws fastening fuel pump to fuel tank 5 Nm (3.69 lb ft) Pre-permeated Rear tank fastening screw 25 Nm (18.44 lb ft) BODYW - 310...
Page 311 V7 III ABS Bodywork • Undo and remove the screw (1) • Retrieve the washer (2) • Partially raise the fuel tank and discon- nect the fuel hose coupling (3) CAUTION PAY PARTICULAR ATTENTION DURING THE LIFTING OP- ERATION IN THAT THE FUEL HOSE FITTING CAN BE DAM- AGED •...
Page 312 V7 III ABS Bodywork • Remove the fuel tank (6) TANK STRAP REMOVAL (RACER/ANNIVERSARIO) • Unhook the tank strap from the point indicated in the figure • Undo and remove the screw (1) • Retrieve the washer (2) and the sup- port hook (3) •...
Page 313: Front Mudguard
V7 III ABS Bodywork Front mudguard RONT MUDGUARD Pos. Description Type Quantity Torque Notes Screws fastening the stabiliser plate to the fork 15 Nm (11.06 lb ft) Loctite 243 Screw fastening the mudguard to the stabiliser 10 Nm (7.38 lb ft) Loctite 243 plate •...
Page 314 V7 III ABS Bodywork • Remove the four screws fixing the mudguard to the mudguard support • Remove the mudguard support from the mudguard BODYW - 314...
Page 315 INDEX OF TOPICS PRE DE DELIVERY...
Page 316 V7 III 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 front and rear brake calliper retainer unit front and rear wheel unit engine - chassis retainers...
Page 317: Road Test
V7 III 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 THE LIFE OF THE BATTERY. CAUTION WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG- ATIVE ONE, AND PERFORM THE REVERSE OPERATION DURING REMOVAL.
Page 318 V7 III ABS Pre-delivery - Front and rear brake efficiency - Front and rear suspension efficiency - Abnormal noise Static test Static check after test drive: - Restarting when warmed up - Starter operation (if present) - Minimum holding (turning the handlebar) - Uniform turning of the steering - Possible leaks - Radiator electric fan operation (if present)
Page 319 ABS: 238, 246 Air filter: 49, 53, 55 Battery: 106, 111 Brake: 252, 254, 256, 258, 260, 261, 265, 266 Brake calliper: 252, 254 Brake disc: 256, 258 Brake lever: Brake pads: 260, 261 Brake pump: 265, 266 Bulbs: CAN line: 151 Clutch: 133 Coil: 129 Connectors: 139...
Page 320 Identification: 10 Instrument panel: Maintenance: 8, 43 Mudguard: 305, 313 Oil filter: 48 Rear light: Rear wheel: 198 Recommended products: 38 Run/Stop switch: 138 SAS valve actuator: 136 Scheduled maintenance: 43 Secondary air system: Shock absorbers: 191 Side stand: 134 Side stand sensor: 134 Spark plugs: Speed sensor: 112...

MOTO GUZZI 2Q000297 Service Station Manual

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