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MOTO GUZZI V7 Racer Service Station Manual
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MOTO GUZZI V7 Racer Service Station Manual

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SERVICE STATION MANUAL
898983
V7 Racer

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Summary of Contents for MOTO GUZZI V7 Racer

  • Page 1 SERVICE STATION MANUAL 898983 V7 Racer...
  • Page 2 Not all versions/models shown in this publication are available in all countries. The availability of individual versions should be checked with the Official Moto Guzzi sales network. © Copyright 2010- Moto Guzzi. All rights reserved. Reproduction of this publication in whole or in part is prohibited. Moto Guzzi - After sales service.
  • Page 3 In order to optimise customer satisfaction when using our vehicles, Moto Guzzi s.p.a. commits itself to continually improve its products and the relative documentation. The main technical modifications and changes in repair procedures are communicated to all Moto Guzzi Sales Outlets and its International Subsidiaries.
  • 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 V7 Racer 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 Racer 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 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 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 Racer Characteristics This number consists of numbers and letters, as in the example shown below. ZGULWB0009MXXXXXX KEY: ZGU: WMI (World manufacturer identifier) code; LW: model; B00: version variation; 0: free digit 9: variable year of manufacture (9 - for 2009) M: production plant (M= Mandello del Lario);...
  • Page 12 V7 Racer Characteristics Specification Desc./Quantity Electric Electric starter Engine idle speed 1100 +/- 100 rpm Intake valve clearance 0.15 mm (0.0059 in) Exhaust valve clearance 0.20 mm (0.0079 in) Clutch dry single-disc clutch with flexible coupling Lubrication Pressure-fed, controlled by valves and trochoidal pump...
  • Page 13 V7 Racer Characteristics BULBS Specification Desc./Quantity Low/high beam light (halogen) 12 V - 55 W / 60 W H4 Front daylight running lights 12V - 5W Turn indicator light 12 V - 10 W (orange RY 10 W bulb) tail light /stop lights...
  • Page 14 V7 Racer Characteristics Specification Desc./Quantity Rear 260 mm (10.24 in) diam. stainless steel disc Wheels and tyres WHEEL RIMS Specification Desc./Quantity Type with spokes, for tyres with inner tubes Front 2.5''x18'' Rear 3.50 x 17'' TYRES Specification Desc./Quantity Front tyre (standard)

  • Page 15: Table Of Contents

    V7 Racer Characteristics Front side RONT SUSPENSION TEERING pos. Description Type Quantity Torque Notes Stanchion cap 50 Nm (36.88 lbf ft) Screw fixing wheel axle to right fork leg M6x30 10 Nm (7.37 lbf ft) Tighten using a 1-2-1 se-...

  • Page 16: Type Quantity Torque

    V7 Racer Characteristics pos. Description Type Quantity Torque Notes Headstock bushing M23x1 50 Nm (36.88 lbf ft) NSTRUMENT PANEL pos. Description Type Quantity Torque Notes Screw fixing instrument panel to headlamp sup- M6x10 10 Nm (7.37 lbf ft) port CHAR - 16...
  • Page 17 V7 Racer Characteristics ANDLEBAR AND ONTROLS Pos. Description Type Quantity Torque Notes Switch fastener screw 1.5 Nm (1.11 lb ft) Tighten using a 1-2-1 se- quence Semi-handlebar fixing screw M6x25 10 Nm (7.37 lb ft) Tighten using a 1-2-1 se-...

  • Page 18: M10X40

    V7 Racer Characteristics RONT LIGHTS pos. Description Type Quantity Torque Notes Headlamp fixing screw M8x30 15 Nm (11.06 lb ft) Front turn indicator fixing screw 5 Nm (3.69 lb ft) Horn fixing screw M6x16 10 Nm (7.37 lb ft) Headlamp support bracket fixing M10x40 50 Nm (36.88 lb ft)

  • Page 19: Notes

    V7 Racer Characteristics ODYWORK RONT SECTION pos. Description Type Quantity Torque Notes Screw fastening stabiliser plate to fork M8x40 15 Nm (11.06 lbf ft) Loctite 243 Screw fastening mudguard to stabiliser M6x11 10 Nm (7.37 lbf ft) Loctite 243 plate Top fairing fixing screw 10 Nm (7.37 lbf ft)
  • Page 20 V7 Racer Characteristics LECTRICAL SYSTEM FRONT pos. Description Type Quantity Torque Notes HV coil fastener screw M4x25 3 Nm (2.21 lbf ft) Timing sensor fastener screw M5x12 6 Nm (4.42 lbf ft) Central part CHAR - 20...
  • Page 21 V7 Racer Characteristics RAME pos. Description Type Quantity Torque Notes Screw fixing tank mounting rubber M8x14 25 Nm (18.44 lbf ft) blocks to frame Cradle front fixing screw M10x30 50 Nm (36.88 lbf ft) Screw fastening gearbox to frame M10x55 50 Nm (36.88 lbf ft)
  • Page 22 V7 Racer Characteristics IDE STAND pos. Description Type Quantity Torque Notes Side stand retainer pin M10x1.2 10 Nm (7.38 lb ft) Lock nut for stand bolt M10x1.2 30 Nm (22.13 lb ft) Switch fixing screw M5x16 6 Nm (4.42 lb ft) UEL TANK pos.
  • Page 23 V7 Racer Characteristics UEL SUPPLY SYSTEM pos. Description Type Quantity Torque Notes Screw fixing fuel pump mounting to M5x16 6 Nm (4.43 lbf ft) tank IR FILTER pos. Description Type Quantity Torque Notes Air filter box cover fastening screw SWP M5x20 3 Nm (2.21 lbf ft)
  • Page 24 V7 Racer Characteristics pos. Description Type Quantity Torque Notes Air filter box half-shells and cover Self-tapp. 3.9x14 3 Nm (2.21 lbf ft) fastening screw Screw fastening air filter box to frame SWP M5x20 3 Nm (2.21 lbf ft) EAR SHIFT pos.
  • Page 25 V7 Racer Characteristics 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 (7.37 lb ft)
  • Page 26 V7 Racer Characteristics ODYWORK CENTRAL SECTION ADDLE pos. Description Type Quantity Torque Notes Saddle release block fixing screw M6x25 10 Nm (2.37 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 27 V7 Racer Characteristics OCK KIT pos. Description Type Quantity Torque Notes (Shear head) screw fixing ignition M8x15 At the point of failure lock Ignition lock fixing screw M8x16 25 Nm (18.44 lb ft) XHAUST SYSTEM Pos. Description Type Quantity Torque...
  • Page 28 V7 Racer Characteristics Back side EAR TRANSMISSION SWINGARM pos. Description Type Quantity Torque Notes Swingarm clamp retaining screw M10x45 30 Nm (22.13 lbf ft) Pin fixing the rear calliper holding M16x1 25 Nm (18.44 lbf ft) plate to swingarm Nut fixing gearcase to swingarm 25 Nm (18.44 lbf ft)
  • Page 29 V7 Racer Characteristics EAR SUSPENSION pos. Description Type Quantity Torque Notes Upper screw fastening shock absorber to M6x35 10 Nm (7.37 lbf ft) Loctite 243 frame Lower pin fastening left shock absorber to M10x1.5 35 Nm (25.81 lbf ft) swingarm Stud bolt fixing right shock absorber to rear M12x1.5...
  • Page 30 V7 Racer Characteristics EAR WHEEL pos. Description Type Quantity Torque Notes Rear wheel axle nut M16x1.5 120 Nm (88.51 lb ft) Rear brake disc fixing screw M8x25 25 Nm (18.44 lb ft) Loctite 243 EAR BRAKE SYSTEM pos. Description Type...
  • Page 31 V7 Racer Characteristics pos. Description Type Quantity Torque Notes Drilled screw for brake pipe on cal- 25 Nm (18.44 lb ft) liper Stud bolt fixing right shock absorber 25 Nm (18.44 lbf ft) to rear box EAR LIGHTS pos. Description...
  • Page 32 V7 Racer Characteristics EAR SECTION BODYWORK ICENSE PLATE MOUNTING pos. Description Type Quantity Torque Notes Screw fastening retroreflector mounting to license M5x10 4 Nm (2.95 lbf ft) plate mounting Nut fixing retroreflector to mounting 4 Nm (2.95 lbf ft) CHAR - 32...
  • Page 33 V7 Racer Characteristics EAR MUDGUARD pos. Description Type Quantity Torque Notes Rear mudguard front and central fixing screw 10 Nm (7.37 lb ft) Rear mudguard side fixing screw M8x30 25 Nm (18.44 lb ft) Screw fixing license plate holder to mudguard 3 Nm (2.21 lb ft)
  • Page 34 V7 Racer Characteristics 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 35 INDEX OF TOPICS S-TOOLS PECIAL TOOLS...
  • Page 36 V7 Racer 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 37 V7 Racer 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 38 INDEX OF TOPICS MAIN AINTENANCE...
  • Page 39 V7 Racer Maintenance Maintenance chart 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 40 V7 Racer Maintenance Transmission fluid 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 41 V7 Racer Maintenance • Screw and tighten the caps (1 - 2). Engine oil Check CAUTION ENGINE MUST BE WARM TO CHECK ENGINE OIL LEVEL. NOTE DO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT STANDSTILL TO WARM UP THE ENGINE OIL AND REACH THE OPERATING TEMPERATURE OF ENGINE OIL.
  • Page 42 V7 Racer Maintenance CAUTION DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCE TO THE FLUID. WHEN USING A FUNNEL OR ANY OTHER EL- EMENT, MAKE SURE IT IS PERFECTLY CLEAN. Replacement • Place a container with + 2000 cm³ (122 cu.in) capacity under the drainage...
  • Page 43 V7 Racer Maintenance Engine oil filter • Loosen the screw (3) and remove the cover (4). • Remove the engine oil filter (5). NOTE NEVER REUSE AN OLD FILTER. • Spread a thin layer of oil on the sealing ring (6) of the new engine oil filter.
  • Page 44 V7 Racer Maintenance • Working on both sides, undo and re- move the two air filter casing cover screws. • Remove the oil breather pipe. • Slide off the air filter casing cover from the right side of the vehicle.
  • Page 45 V7 Racer Maintenance Braking system RONT BRAKE SYSTEM pos. Description Type Quantity Torque Notes Screw fastening the brake pump U-bolt to the 10 Nm (7.37 lbf ft) Tighten using a 1-2-1 se- semi-handlebar quence Front brake calliper fixing screw M10x30 50 Nm (36.88 lb ft)
  • Page 46 V7 Racer Maintenance EAR BRAKE SYSTEM pos. Description Type Quantity Torque Notes Rear brake calliper fixing screw M8x35 25 Nm (18.44 lbf ft) Drilled screw for brake pipe on cal- 25 Nm (18.44 lb ft) liper Stud bolt fixing right shock absorber 25 Nm (18.44 lbf ft)
  • Page 47 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 - 47...
  • Page 48 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 49 V7 Racer Electrical system LECTRICAL SYSTEM FRONT pos. Description Type Quantity Torque Notes HV coil fastener screw M4x25 3 Nm (2.21 lbf ft) Timing sensor fastener screw M5x12 6 Nm (4.42 lbf ft) LECTRICAL SYSTEM REAR pos. Description Type Quantity...
  • Page 50 V7 Racer Electrical system pos. Description Type Quantity Torque Notes Electronic control unit fixing screw SWP M5x20 3 Nm (2.21 lbf ft) Speedometer sensor fastener screw M6x12 10 Nm (7.37 lbf ft) Fuse box bracket fixing screw M5x12 4 Nm (2.95 lbf ft)
  • Page 51 V7 Racer Electrical system 1. Instrument panel 2. Coil 3. Fuel pump 4. Throttle potentiometer (TPS) 5. Injector 6. Fall sensor 7. Rear light 8. Battery 9. Instrument panel air sensor 10.Control unit 11.Speed sensor 12.Intake air temperature sensor 13.Engine revolution sensor 14.Head temperature sensor...
  • Page 52 V7 Racer Electrical system is also important and essential for the correct op- eration of the vehicle. Vehicle sections The wiring distribution is subdivided in three es- sential sections, as indicated in the figure. 1. Front section 2. Central section 3.
  • Page 53 V7 Racer Electrical system TABLE D Insert the throttle control and starter transmissions through the cable guide on the steering pipe (4) and fasten them with a rubber clamp (5). TABLE E Turn the steering to the left, clamp the three cables of the front cable harness with two clamps: •...
  • Page 54 V7 Racer Electrical system TABLE B Clamp the tank drainage pipes to the ground with the oil scavenge pipes so that they do not touch the compensator. CAUTION DO NOT SQUEEZE THE TWO TUBES WHILE FASTENING THE CLAMP. TABLE C - RELAY POSITION 1.
  • Page 55 V7 Racer Electrical system TABLE F - TIMING SWITCH SYSTEM POSITION Clamp the timing sensor system to the generator system, regulator system, horn system and left ca- ble of the chassis cross member. CAUTION DO NOT SQUEEZE THE TWO TUBES WHILE FASTENING THE CLAMP.
  • Page 56 V7 Racer Electrical system General wiring diagram Key: 1. Multiple connectors 2. Revolution sensor 3. Oil pressure sensor 4. Left coil ELE SYS - 56...
  • Page 57 V7 Racer Electrical system 5. Right coil 6. Spark plugs 7. Left injector 8. Right injector 9. Fuel pump 10.Fuel reserve sensor 11.Main injection relay (polarised) 12.Secondary injection relay 13.Side stand switch 14.Lambda Probe 15.Throttle sensor 16.Engine air thermistor 17.Head temperature sensor 18.Voltage regulator...
  • Page 58 V7 Racer Electrical system 43.Instrument panel 44.Speed sensor 45.External air temperature thermistor 46.Right front turn indicator 47.High - low-beam bulb 48.Front tail light bulb 49.Front headlamp 50.Left front turn indicator 51.ECU 52.Diagnostics socket Cable colour: Ar orange Az sky blue...
  • Page 59 V7 Racer 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 60 V7 Racer Electrical system Specification Desc./Quantity Front daylight running lights 12V - 5W Turn indicator light 12 V - 10 W (orange RY 10 W bulb) License plate light 12V - 5 W tail light /stop lights 12 V - 5 / 21 W...
  • Page 61 V7 Racer Electrical system Control unit Magneti Marelli engine control unit 15 RC Battery Characteristic Battery 12V - 12 Ah Speed sensor Function To indicate the vehicle speed by reading the rear wheel rotation speed. Operation / Operating principle Hall effect sensor: a square-wave pulse is gener- ated with voltage between 12V and approximately 0.6 V.
  • Page 62 V7 Racer Electrical system PIN: • PINS 1-3 Voltage: approximately 12 V • PINS 2-3 Voltage: between 0.6V-12V (turning the rear wheel) 1. Supply voltage (green - sensor side) 2. Output signal (grey/white - sensor side) 3. Ground (blue/orange - sensor side)
  • Page 63 V7 Racer Electrical system • Winding resistance: 650 Ω ± 15% Out- put alternating voltage, value range: minimum: 0.5 V - maximum: 5 V Pin-out: 1. Engine speed sensor positive signal 2. Engine speed sensor negative signal 3. Engine speed sensor anti-jamming cable...
  • Page 64 V7 Racer Electrical system Throttle position sensor Function In charge of telling the control unit the position of the throttle valves. Operation / Operating principle The throttle valve position sensor works as a var- iable resistance according to the throttle rotation.
  • Page 65 V7 Racer Electrical system of the control unit connector and PIN C of the sensor (brown/yellow cable): if there is not continuity, restore the cable harness; if there is continuity, check continuity of the sensor between PIN A and PIN C: if there is not continuity, replace the potentiometer; if there is continuity, measure the resistance.
  • Page 66 V7 Racer Electrical system • Resistance at 0°C: 9.75 kΩ ± 5% • Resistance at 20°C: 3.747 kΩ ± 5% • Resistance at 40°C: 1.598 kΩ ± 5% • Resistance at 60°C: 0.746 kΩ ± 5% • Resistance at 80°C: 0.377 kΩ ± 5% •...
  • Page 67 V7 Racer Electrical system Air temperature sensor Function It tells the control unit the intake air temperature in order to calculate oxygen presence so as to opti- mise the petrol quantity necessary for correct com- bustion. Operation / Operating principle NTC type sensor (resistance sensor, inversely variable with temperature).
  • Page 68 V7 Racer Electrical system • If the circuit is open, shorted to positive: check sensor connector and Marelli control unit connector; if not OK, restore cable harness; if OK, check sensor continuity; if it is not OK, replace the sensor; if it is OK, check the continuity between PIN 18 of the control unit con- nector and the PIN related to the pink/black cable (cable harness side) of the sensor: restore cable harness if there is not continuity;...
  • Page 69 V7 Racer Electrical system Electrical characteristics: Heater circuit: 12 -14 Ω at 20 °C (68 °F) Pin-out: 1. Sensor signal + (black wire) 2. Sensor signal - (grey wire) 3. Heater ground connection (white) 4. Heater power supply (white) NAVIGATOR: PARAMETERS...
  • Page 70 V7 Racer Electrical system Error cause • Short circuit/open circuit: lambda probe that does not get into cycle. Troubleshooting • Disconnect the connector and check that the heater resistance (on 2 white cables) is ap- proximately 13 Ohm (at room temperature). If it is OK, check if there is ground connection on PIN 4 (blue cable) on the cable harness side;...
  • Page 71 V7 Racer Electrical system NAVIGATOR: ELECTRICAL ERRORS Left injector - shorted to positive / shorted to negative / open circuit. Error cause • If shorted to positive: excessive voltage has been detected at PIN 13 of the control unit connector.
  • Page 72 V7 Racer Electrical system • If shorted to positive: disconnect the injector connector, set the key to ON and check if there is voltage on the yellow/red cable: if there is voltage, restore the cable harness; if there is not, replace the injector.
  • Page 73 V7 Racer Electrical system Left coil: The auxiliary injection relay (No. 12 in the wiring diagram, placed under saddle, second relay starting from the front; CHECK, however, the identification of the relay with the colour of the cables) is energised for 5 seconds and the orange/white cable of the coil is closed to ground for 2 ms per second.
  • Page 74 V7 Racer Electrical system • shorted to positive: disconnect the coil connector, set the key to ON, activate the coil with Navigator and check voltage at connector PIN 2: if there is voltage, restore the cable har- ness; if voltage = 0, replace the coil.
  • Page 75 V7 Racer Electrical system • Disconnect the sensor connector and check the ground insulation of the purple cable: if there is continuity with the ground connection, restore the cable harness; if earth insulated, replace the switch. if the error remains, check oil pressure in the engine circuit with a pressure gauge...
  • Page 76 V7 Racer Electrical system Operation / Operating principle To start-up the engine, pull the clutch with gear in neutral. Level in wiring diagram:Start-up enabling switches. Location: • sensor: under clutch lever • connector: under the fuel tank Electrical characteristics: •...
  • Page 77 V7 Racer Electrical system • Side Stand Up: closed circuit (continuity) • Side Stand Down: open circuit (infinite resistance) Pin-out: • Blue (cable harness side): Ground connection • Green/brown (cable harness side): voltage 12V DIAGNOSIS • The vehicle with clutch pulled, gear engaged and side stand retracted does not start (side...
  • Page 78 V7 Racer Electrical system • Sensor inverted: closed circuit (resist- ance lower than 0.5 kOhm) Pin-out: • Pink/yellow (cable harness side): Volt- age 12V • Grey (cable harness side): ground con- nection DIAGNOSIS The vehicle starts, even if the sensor is inverted: disconnect the connector and, with sensor inverted, check if there is continuity between the two PINS of the sensor: if there is not continuity, replace the sensor;...
  • Page 79 V7 Racer Electrical system Pin-out: 1. Voltage 5V 2. Ground connection DIAGNOSIS "---" code that indicates an instrument panel error Air temperature sensor fault Error cause • An instrument panel temperature sensor failure is signalled when it is detected that the...
  • Page 80 V7 Racer Electrical system • STOP position: the circuit is open • RUN position: closed circuit (continuity) PIN: red/grey cable (watching the cable harness): • voltage 0 V with engine kill in STOP; • 12 V with engine kill in RUN.
  • Page 81 V7 Racer Electrical system 7. Engine revolution sensor - Frequency input 8. Lambda probe signal (positive) - Analogue input 9. Diagnosis line (K) - Communication line 10.Diagnosis line (L) - Communication line 11.Throttle position signal - Analogue input 12.Engine revolution sensor - Frequency input 13.Right injector control - Power output...
  • Page 82 V7 Racer Electrical system 13.Speed sensor power supply 14.Ground connection 15.K Line 16.n.c. 17.Speed input 18.Engine revs input 19.n.c. 20.Reserve input 21.Key 22.Ground connection 23.Battery 24.Front right arrow output 25.Rear right arrow output 26.Battery ELE SYS - 82...
  • Page 83 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 84 V7 Racer Engine from vehicle Vehicle preparation • Before removing the engine block, re- move the fuel tank, the battery, the exhaust pipes, the shock absorbers and the rear wheel. • Disconnect the speed sensor connec- tion and slide off the cable from the cable harness.
  • Page 85 V7 Racer Engine from vehicle pos. Description Type Quantity Torque Notes Preselector lever fixing screw M6x20 10 Nm (7.37 lb ft) Gearbox lever fixing screws M6x20 10 Nm (7.37 lb ft) Loctite 243 Gearbox control rod fixing nut M6x1 10 Nm (7.37 lb ft) Screw fastening rider footrest mount- 20 Nm (14.75 lb ft)
  • Page 86 V7 Racer Engine from vehicle • Remove the injectors lock and slide in- jectors off there seat on the inlet mani- folds. • Disconnect the spark plug cables from the coils and slide them off the chassis. ENG VE - 86...
  • Page 87 V7 Racer Engine from vehicle • Loosen the clamps on the intake mani- folds. • Disconnect the oil breather pipe on the cylinder heads. • Remove the connection of the engine temperature sensor. • Disconnect the starter motor and the lambda probe.
  • Page 88 V7 Racer Engine from vehicle • Open the clamp and disconnect the oil breather pipe of the air filter casing. • Disconnect the neutral indicator. • Disconnect the connector of the side stand safety switch and slide off the cable harness from the chassis.
  • Page 89 V7 Racer Engine from vehicle • Undo and remove the screw. • Remove the gear transmission lever. • Undo and remove the two right footrest screws, move the rear brake pedal that is still attached to the tank and to the calliper.
  • Page 90 V7 Racer Engine from vehicle • Remove the rod fixing the chassis to the gearbox . • Remove the engine: check that during the removal operation, the throttle body sleeves slide off the inlet mani- folds without getting damaged. •...
  • Page 91 V7 Racer Engine from vehicle Installing the engine to the vehicle RAME CRADLES pos. Description Type Quantity Torque Notes Screw fixing stand beam to cradle M10x260 50 Nm (36.88 lbf ft) Screw fixing stand beam to cradle 25 Nm (18.44 lbf ft)
  • Page 92 V7 Racer Engine from vehicle RAME pos. Description Type Quantity Torque Notes Screw fixing tank mounting rubber M8x14 25 Nm (18.44 lbf ft) blocks to frame Cradle front fixing screw M10x30 50 Nm (36.88 lbf ft) Screw fastening gearbox to frame M10x55 50 Nm (36.88 lbf ft)
  • Page 93 V7 Racer Engine from vehicle • Fit the screw fixing the ground eyelet on the engine block. • Restore the connection of the side stand safety switch. • Connect the neutral indicator. • Insert the oil breather pipe in the air fil- ter casing and lock it with the corre- sponding clamp.
  • Page 94 V7 Racer Engine from vehicle • Connect the starter motor and the lambda probe. • Restore the connection of the engine temperature sensor. • Insert the breather pipes on the cylin- der heads and lock them with the spe- cific clamps.
  • Page 95 V7 Racer Engine from vehicle • Tighten the clamps on the intake mani- folds. • Insert the injectors in their positions and fit the locking ring, tightening the screw to the prescribed torque. • Connect the spark plug cables on the ignition coils.
  • Page 96 V7 Racer Engine from vehicle • Place the clutch linkage and insert the pin on the engine block, locking it with the corresponding split pin. • Refit the swingarm and the bevel gear pair. ENG VE - 96...
  • Page 97 V7 Racer Engine from vehicle • Fit the revolution sensor by tightening the screws to the prescribed torque. • Restore the electrical connections of the generator. • Restore the connection of the vehicle speed sensor. ENG VE - 97...
  • Page 98 INDEX OF TOPICS NGINE...
  • Page 99 V7 Racer Engine TO CONSULT THE CHAPTER ABOUT THE ENGINE AND ITS COMPONENTS PLEASE REFER TO THE APPROPRIATE MANUAL: "MSS Engine V750 IE" ENG - 99...
  • Page 100 INDEX OF TOPICS P SUPP OWER SUPPLY...
  • Page 101 V7 Racer 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 - 101...
  • Page 102 V7 Racer 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 103 V7 Racer Power supply 13.Fall sensor 14.Side stand Cylinders synchronisation • With engine off, connect the Navigator tool to the diagnosis connector and to the vehicle battery. • Turn on the scanner. • Screw the joints connecting the vacu- ometer pipes on the intake pipe holes.
  • Page 104 V7 Racer Power supply • Take the engine to an out-of-idle speed: 2000 - 3000 rpm. • Check cylinder compensation on the vacuometer. • To correct compensation use the set screw of the control rod of the throttle bodies, on the left side of the vehicle, until cylinders are compensated.
  • Page 105 V7 Racer Power supply 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 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 106 V7 Racer Power supply Specification Desc./Quantity Higher not synchronised timing of a tooth Number of engine timing steps during which the revolution tim- ing sensor has lost the signal of more than one tooth. Engine rpm Engine revolutions per minute: the minimum value is set by the...
  • Page 107 V7 Racer Power supply DEVICES ACTIVATION Specification Desc./Quantity Error clearing By pressing the 'enter' button, the stored errors (MEM) become part of the historical data (STO). In the next connection be- tween the Navigator and the control unit, the historical errors...
  • Page 108 V7 Racer Power supply SETTINGS screen page This screen page is used to adjust some control unit parameters. ADJUSTABLE PARAMETERS Specification Desc./Quantity Throttle positioner autodetection Allows the control unit to detect the closed throttle position: just press the enter button...
  • Page 109 INDEX OF TOPICS SUSP USPENSIONS...
  • Page 110 V7 Racer Suspensions Front RONT WHEEL pos. Description Type Quantity Torque Notes Front wheel axle M18x1.5 80 Nm (59.00 lbf ft) Front brake disc fixing screw M8x20 25 Nm (18.44 lbf ft) Loctite 243 Removing the front wheel • Place the vehicle on a stable support so that the front wheel does not touch the ground.
  • Page 111 V7 Racer Suspensions Handlebar ANDLEBAR AND ONTROLS Pos. Description Type Quantity Torque Notes Switch fastener screw 1.5 Nm (1.11 lb ft) Tighten using a 1-2-1 se- quence Semi-handlebar fixing screw M6x25 10 Nm (7.37 lb ft) Tighten using a 1-2-1 se-...
  • Page 112 V7 Racer Suspensions Front fork RONT SUSPENSION TEERING pos. Description Type Quantity Torque Notes Stanchion cap 50 Nm (36.88 lbf ft) Screw fixing wheel axle to right fork leg M6x30 10 Nm (7.37 lbf ft) Tighten using a 1-2-1 se-...
  • Page 113 V7 Racer Suspensions pos. Description Type Quantity Torque Notes Headstock bushing M23x1 50 Nm (36.88 lbf ft) Diagram Key: 1. Screw 2. Washer 3. Screw 4. Complete left sleeve 5. Upper bushing 6. Washer 7. Sealing ring 8. Snap ring 9.
  • Page 114 V7 Racer Suspensions 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.Complete right sleeve 30.Lower U-bolt 31.Upper U-bolt 32.Screw 33.Screw 34.O-ring 35.Stem protection 36.Chrome-plated cap 37.Gasket kit 38.Oil seal kit Removing the fork legs...
  • Page 115 V7 Racer Suspensions • Remove the front mudguard. • 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 116 V7 Racer Suspensions Draining oil To drain out the oil follow these steps. • Remove the stanchion. • Tighten the removed stanchion in a vice fitted with aluminium jaw caps in order to avoid damaging them. • Unscrew the upper closing cap. Pay attention to the possible thrust that the spring can cause to the loosened cap.
  • Page 117 V7 Racer Suspensions • Remove the shim. • 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.
  • Page 118 V7 Racer Suspensions Disassembling the fork • Drain all the oil from the stem. • Block the wheel holder fork leg on the vice. • Undo the bottom screw and remove it with the corresponding gasket. • Remove the dust scraper using a screwdriver as a lever.
  • Page 119 V7 Racer Suspensions • Slide off the bearing tube from the wheel holder fork leg together with the sealing ring, the cap, the upper bush- ing and lower bushings. NOTE WHEN REMOVING THE PIPE FROM THE WHEEL HOLDER FORK LEG SOME PARTS MAY REMAIN INSIDE THE FORK LEG.
  • Page 120 V7 Racer Suspensions • Check that the upper guide bushing is fitted on the wheel holder fork leg. • Insert the lower sliding bushing in its seat on the bearing tube. • Reassemble the bearing tube in the wheel holder fork leg.
  • Page 121 V7 Racer Suspensions • Screw the bottom screw and tighten it to the prescribed torque. • Insert the cap and the well-lubricated sealing ring on the bearing tube. • Use a suitable inserting tool to push the sealing ring in the fork leg until it stops.
  • Page 122 V7 Racer Suspensions Filling oil • Place the sleeve upright in a vice fitted with protection jaws. • Compress the sleeve in the stanchion. • Pour part of the fork oil into the sleeve. • Wait some minutes until the oil fills all the ducts.
  • Page 123 V7 Racer Suspensions • 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 • Insert the stem on the vehicle going through the lower plate and the upper plate.
  • Page 124 V7 Racer Suspensions • Tighten the screws to the prescribed torque. SUSP - 124...
  • Page 125 V7 Racer Suspensions Steering bearing RONT SUSPENSION TEERING pos. Description Type Quantity Torque Notes Stanchion cap 50 Nm (36.88 lbf ft) Screw fixing wheel axle to right fork leg M6x30 10 Nm (7.37 lbf ft) Tighten using a 1-2-1 se-...
  • Page 126 V7 Racer Suspensions pos. Description Type Quantity Torque Notes Headstock bushing M23x1 50 Nm (36.88 lbf ft) Adjusting play • Undo and remove the screws and col- lect the U-bolt, holding the handlebar. • Move the handlebar forward, be care- ful not to turn over the front brake fluid reservoir.
  • Page 127 V7 Racer Suspensions • 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. • Fit the handlebar.
  • Page 128 V7 Racer Suspensions Shock absorbers EAR SUSPENSION pos. Description Type Quantity Torque Notes Upper screw fastening shock absorber to M6x35 10 Nm (7.37 lbf ft) Loctite 243 frame Lower pin fastening left shock absorber to M10x1.5 35 Nm (25.81 lbf ft)
  • Page 129 V7 Racer Suspensions • Undo and remove the lower screw. SUSP - 129...
  • Page 130 INDEX OF TOPICS CHAS HASSIS...
  • Page 131 V7 Racer Chassis Swinging arm EAR TRANSMISSION SWINGARM pos. Description Type Quantity Torque Notes Swingarm clamp retaining screw M10x45 30 Nm (22.13 lbf ft) Pin fixing the rear calliper holding M16x1 25 Nm (18.44 lbf ft) plate to swingarm Nut fixing gearcase to swingarm 25 Nm (18.44 lbf ft)
  • Page 132 V7 Racer Chassis EAR WHEEL pos. Description Type Quantity Torque Notes Rear wheel axle nut M16x1.5 120 Nm (88.51 lb ft) Rear brake disc fixing screw M8x25 25 Nm (18.44 lb ft) Loctite 243 Removing • Remove the left silencer.
  • Page 133 V7 Racer Chassis • Remove the rear calliper, releasing the brake pipe from the retainers on the swingarm. • Unscrew and remove the fixing screw of the calliper holder. • Remove both rear suspensions. • Unscrew and remove the nut and col- lect the washer.
  • Page 134 V7 Racer Chassis • Loosen the wheel pin locking screw. • Remove the wheel pin and collect the spacer. • Remove the rear wheel. • Unscrew the seal clamp. • Lift the bellows. CHAS - 134...
  • Page 135 V7 Racer Chassis • Unscrew the nuts. • 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 136 V7 Racer Chassis Installing • Insert the swingarm on the gearbox cover. • Tighten thoroughly the pin on the left side until the shimming washer on the right side rests on the bearing fitted on the gearbox cover. • Tighten thoroughly the pin on the right side, without locking it.
  • Page 137 V7 Racer Chassis • Fit the rear wheel. 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. • Slide off the spring.
  • Page 138 V7 Racer 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 139 V7 Racer 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 140 V7 Racer 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 141 V7 Racer 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 142 V7 Racer 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 143 V7 Racer 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 144 V7 Racer 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 - 144...
  • Page 145 V7 Racer Chassis • Slide off the bearing from the cover us- ing the suitable punch. • Remove the external ring of the needle bearing from the housing using the suitable extractor (19927500). • Remove the sealing ring and the wash- Controllo •...
  • Page 146 V7 Racer 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 147 V7 Racer 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 148 V7 Racer Chassis • If the contact is like this, the pinion is too near the rotation axis of the crown: detach the pinion by reducing spacer thickness • If the contact is like this, the pinion is too far from the rotation axis of the...
  • Page 149 V7 Racer Chassis • 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). • Fit the bearing on the cover using the suitable punch.
  • Page 150 V7 Racer 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 151 V7 Racer Chassis • 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. • Fit the braking disc on the drilled bolt by locking the screws with the washers using a torque wrench.
  • Page 152 V7 Racer Chassis • 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 153 V7 Racer 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. Exhaust XHAUST SYSTEM Pos. Description Type Quantity Torque Notes Exhaust pipe fixing nut to the engine 10 Nm (7.37 lb ft)
  • Page 154 V7 Racer Chassis Pos. Description Type Quantity Torque Notes Exhaust pipe fixing clamp screw to 10 Nm (7.37 lb ft) the compensator Compensator fixing clamp screw to 10 Nm (7.37 lb ft) the silencer Lambda probe on compensator M18x1.5 38 Nm (28.03 lb ft) Nut fastening silencer to mounting 25 Nm (18.44 lb ft)
  • Page 155 V7 Racer Chassis 15.Right silencer clamp 16.Muffler rubber ring 17.TCEI screw 18.Silencer fixing bushing 19.Nut 20.Clip 21.Lambda Probe 22.Spacer 23.Cap 24.Gasket 25.Protection 26.U-bolt 27.TBEI screw 28.Bushing 29.Insulating washer 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 156 V7 Racer Chassis Removing the lambda sensor • Disconnect the lambda probe connec- tor. • Unscrew and remove the lambda sen- sor. CHAS - 156...
  • Page 157 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
  • Page 158 V7 Racer Braking system Rear brake calliper EAR BRAKE SYSTEM 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 1.
  • Page 159 V7 Racer Braking system 2. Plate-torque 3. Brake calliper mounting plate 4. Bushing 5. Spacer 6. Rubber rear brake pipe / Braid rear brake pipe 7. Hydraulic switch 8. Gasket 9. TE Flanged screw 10. Washer 8.4x15 11. Pins + Calliper springs 12.
  • Page 160 V7 Racer Braking system Remove the calliper Installing Fit the rear brake calliper correctly Fit the brake calliper fixing screws by tighten them to the prescribed torque making sure to insert the washers. BRAK SYS - 160...
  • Page 161 V7 Racer Braking system Front brake calliper RONT BRAKE SYSTEM pos. Description Type Quantity Torque Notes Screw fastening the brake pump U-bolt to the M6x25 10 Nm (7.37 lb ft) semi-handlebar Front brake calliper fixing screw M10x30 50 Nm (36.88 lb ft) Drilled screw for brake fluid pipe on pump and 25 Nm (18.44 lb ft)
  • Page 162 V7 Racer Braking system 1. Front brake pump 2. Brake pipe 3. M6x12 TE flanged screw 4. TBEI M4x12 screw 5. Stop switch 6. Pump cover 7. U-bolt 8. Lever pin 9. Brake lever 10. Bleeding+hood 11. Pins + Calliper springs 12.
  • Page 163 V7 Racer Braking system Place the fixing screws (1) of the brake calliper and tighten them to the prescribed torque. Remove the fixing screws (1), making sure to col- lect the spacers (2) Remove the front brake calliper (3) Rear brake disc Removal •...
  • Page 164 V7 Racer Braking system • Unscrew and remove the six brake disc screws (1). • Remove the brake disc (2). UPON REFITTING, APPLY LOCTITE 243 ON THE THREAD OF THE BRAKE DISC SCREWS (1). CAUTION UPON REFITTING, SCREW ALL THE SCREWS (1) MAN- UALLY AND TIGHTEN THEM OPERATING DIAGONALLY FOLLOWING THIS SEQUENCE: A-B-C-D-E-F.
  • Page 165 V7 Racer Braking system • Unscrew and remove the six brake disc screws (1). • Remove the brake disc (2). UPON REFITTING, APPLY LOCTITE 243 ON THE THREAD OF THE BRAKE DISC SCREWS (1). CAUTION UPON REFITTING, SCREW ALL THE SCREWS (1) MAN- UALLY AND TIGHTEN THEM OPERATING DIAGONALLY FOLLOWING THIS SEQUENCE: A-B-C-D-E-F.
  • Page 166 V7 Racer 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 167 V7 Racer Braking system Collect the protection plate. Remove the brake pads Installing Install the brake pads Install the protection plate making sure to direct the arrow, that must be pointed upwards. BRAK SYS - 167...
  • Page 168 V7 Racer Braking system Insert the locking pins of the pads making sure to also lock the protection plate. Lock the pins with a seeger ring. Rear brake pads Removal Remove the rear brake calliper Remove the screws locking the brake pads...
  • Page 169 V7 Racer Braking system Remove the brake pads Installing Install the brake pads Place and tighten the fixing screws of the brake pads to the prescribed torque 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 170 V7 Racer Braking system THE VEHICLE MUST BE ON LEVEL GROUND TO BE PURGED. WHILE PURGING THE HYDRAUL- IC SYSTEM, FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID. CHECK THAT, DURING THE OPERATION, THERE IS ALWAYS BRAKE FLUID IN THE RESER- VOIR.
  • Page 171 V7 Racer 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 172 V7 Racer Braking system RONT BRAKE SYSTEM pos. Description Type Quantity Torque Notes Screw fastening the brake pump U-bolt to the M6x25 10 Nm (7.37 lb ft) semi-handlebar Front brake calliper fixing screw M10x30 50 Nm (36.88 lb ft) Drilled screw for brake fluid pipe on pump and 25 Nm (18.44 lb ft)
  • Page 173 V7 Racer Braking system Installing Connect the front brake pipe fitting Connect the brake switch connectors Place the calliper correctly and fix it with the spe- cial screws to the prescribed tightening torque Fill up the brake system with the relative bleeding procedure to avoid air bubbles in the system.
  • Page 174 V7 Racer Braking system EAR BRAKE SYSTEM 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 (V7 RACER) IDER FOOTREST EAR SHIFT LEVER pos.
  • Page 175 V7 Racer Braking system Rimozione Remove the screws fixing the protection plate, making sure to recover the spacer washers Take the pump from the brake pump shaft BRAK SYS - 175...
  • Page 176 V7 Racer Braking system Remove the brake pipe by acting on the fitting and empty the system to be able to remove the com- plete pump. Installazione Connect the rear pump brake pipe fitting and tight- en it to the prescribed torque...
  • Page 177 INDEX OF TOPICS BODYW ODYWORK...
  • Page 178 V7 Racer Bodywork ODYWORK RONT SECTION pos. Description Type Quantity Torque Notes Screw fastening stabiliser plate to fork M8x40 15 Nm (11.06 lbf ft) Loctite 243 Screw fastening mudguard to stabiliser M6x11 10 Nm (7.37 lbf ft) Loctite 243 plate Top fairing fixing screw 10 Nm (7.37 lbf ft)
  • Page 179 V7 Racer Bodywork EAR SECTION BODYWORK ICENSE PLATE MOUNTING pos. Description Type Quantity Torque Notes Screw fastening retroreflector mounting to license M5x10 4 Nm (2.95 lbf ft) plate mounting Nut fixing retroreflector to mounting 4 Nm (2.95 lbf ft) Fuel tank UEL TANK pos.
  • Page 180 V7 Racer Bodywork • Unscrew and remove the rear screw. • Disconnect the connector. • Disconnect the fuel pipe. • Remove the fuel breather pipe. • Remove the fuel tank by sliding it off and back. BODYW - 180...
  • Page 181 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 182 V7 Racer 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 183 V7 Racer Pre-delivery - Through the diagnosis tool, check that the last mapping version is present in the control unit/s and, if required, program the control unit/s again: consult the technical service website to know about available upgrades and details regarding the operation.
  • Page 184 V7 Racer 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 185 V7 Racer Pre-delivery Specific operations for the vehicle 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 186 V7 Racer 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 187 V7 Racer Pre-delivery • Lock the bolt with the Seeger ring. NOTE REPEAT THE STEPS TO FIT THE PASSENGER FOOTPEG ON THE OPPOSITE SIDE. Turning the shock absorbers upside-down and fitting the passenger handgrips • Remove the two shock absorber fixing screws.
  • Page 188 V7 Racer Pre-delivery SADDLE ODYWORK CENTRAL SECTION ADDLE pos. Description Type Quantity Torque Notes Saddle release block fixing screw M6x25 10 Nm (2.37 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 189 V7 Racer Pre-delivery • Place the two-seat saddle. PRE DE - 189...
  • Page 190 Air filter: 43 Air temperature sensor: 67, 78 Battery: 61 Brake: 158, 161, 163, 164, 166, 168, 171, 173 Brake calliper: 158, 161 Brake disc: 163, 164 Brake lever: Brake pads: 166, 168 Brake pump: 171, 173 Bulbs: Clutch: 75 Coil: 72 Connectors: 80 Display:...
  • Page 191 Oil filter: 43 Oil pressure sensor: 74 Rear wheel: Recommended products: 34 Run/Stop switch: 79 Saddle: Shock absorbers: 128 Side stand: 76 Side stand sensor: 76 Spark plugs: Speed sensor: 61 Stand: 76 Start-up: 59 Tank: 179 Transmission: 12, 40 Tyres: 14 Warning lights: Wiring diagram: 56...