MOTO GUZZI V7 E5 Special-Stone Service Station Manual

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SERVICE STATION MANUAL

2Q000466

V7 E5 Special-Stone

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Page 1 SERVICE STATION MANUAL 2Q000466 V7 E5 Special-Stone...
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 PRE DE DELIVERY 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...
Page 6 INDEX OF TOPICS PRE DE DELIVERY...
Page 7 V7 E5 Special-Stone 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 8 V7 E5 Special-Stone 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 9 V7 E5 Special-Stone Pre-delivery • Check that air bubbles come out of the cells; let the liquid flow into the cells for at least 20 minutes. • If no air bubbles escape and the liquid does not flow, tap lightly on the bottom of the container until the liquid begins to flow into the cells.
Page 10 V7 E5 Special-Stone Pre-delivery - 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...
Page 11 V7 E5 Special-Stone Pre-delivery • Svitare il dado che blocca i componenti dello specchio e rimuoverlo prestando particolare attenzione al verso di mon- taggio delle molle a tazza (1) che dev- ono avere la parte concava verso l'esterno. • In caso di mancanza del grasso, appli- care un velo su ambo i lati delle molle a tazza (1).
Page 12 V7 E5 Special-Stone Pre-delivery • Serrare alla coppia di 10 Nm (7.38 lbf ft) la vite per il fissaggio dello specchio retrovisore a manubrio. • Mantenendo ferma la vite, ruotare da ambo i lati lo specchio per un paio di volte.
Page 13 INDEX OF TOPICS CHAR HARACTERISTICS...
Page 14 V7 E5 Special-Stone 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 15 V7 E5 Special-Stone 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 16 REASSEMBLING THE COMPONENTS CAUTION THE BEARING MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE THEY MUST BE REPLACED. • Only use ORIGINAL Moto Guzzi SPARE PARTS. • Comply with lubricant and consumables use guidelines. • Lubricate parts (whenever possible) before reassembling them.
Page 17 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 18 V7 E5 Special-Stone Characteristics CHASSIS NUMBER The chassis number is stamped on the RH side of the headstock. This number consists of numbers and letters, as in the example shown below. ZGULD00017MXXXXXX KEY: ZGU: WMI (World Manufacturer Identifier) code; LD: model;...
Page 19 V7 E5 Special-Stone Characteristics Specification Desc./Quantity Idle engine speed 1,250 +/- 100 (rpm) Clutch single disc dry clutch with flexible coupling Lubrication system pressure-fed, controlled by valves and trochoidal pump Air filter cartridge-type dry filter Cooling Transmission GEARBOX Specification Desc./Quantity...
Page 20 V7 E5 Special-Stone Characteristics INDICATOR LAMPS 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)
Page 21 V7 E5 Special-Stone Characteristics Wheels and tyres WHEEL RIMS Specification Desc./Quantity Type spoked wheels with alloy rims, for tyres with inner tubes, or alloy tubes wheels for tubeless tyres. Front 2.5''x18'' Rear 4.25" x 17'' TYRES Specification Desc./Quantity Front (size)
Page 22 V7 E5 Special-Stone Characteristics Front side RONT SUSPENSION TEERING Pos. Description Type Quantity Torque Notes Screws fastening stanchion on upper plate M8x35 25 Nm (18.44 lbf 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...
Page 23 V7 E5 Special-Stone Characteristics Pos. Description Type Quantity Torque Notes Connector plate fastening screw M6x16 10 Nm (7.38 lbf ft) Screws fastening stanchion on lower plate 45 Nm (33.19 lb ft) Pumping unit fastening screw 50 Nm (36.88 lb ft)
Page 24 V7 E5 Special-Stone Characteristics NSTRUMENT CLUSTER Pos. Description Type Quantity Torque Notes Instrument cluster cover fastening screws Self-tap- 2 Nm (1.46 lbf ft) ping 4.2x13 Screws fastening instrument cluster to support Self-tap- 3 Nm (2.21 lbf ft) bracket ping 5x14 Support plate fastening screws 10 Nm (7.38 lbf ft)
Page 25 V7 E5 Special-Stone 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 lbf ft) Mirror fixing Manual Light switch fastening screws SWP 5 1.5 Nm (1.11 lb ft)
Page 26 V7 E5 Special-Stone Characteristics EADLIGHT UNIT 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 10 Nm (7.38 lbf ft)
Page 27 V7 E5 Special-Stone Characteristics EADLIGHT UNIT 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 10 Nm (7.38 lbf ft) RONT MUDGUARD Pos.
Page 28 V7 E5 Special-Stone 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 lbf ft) Loctite 243 ABS-sensor fixing stud bolt 6 Nm (4.43 lbf ft)
Page 29 V7 E5 Special-Stone 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 lbf ft) Loctite 243 ABS-sensor fixing stud bolt 6 Nm (4.43 lbf ft)
Page 30 V7 E5 Special-Stone Characteristics Central part RAME Pos. Description Type Quantity Torque Notes Screws fastening the tank support 25 Nm (18.44 lbf ft) buffers to the frame Front cradle fixing screws 50 Nm (36.88 lb ft) Pre-permeated Screw fastening the stand cross- 50 Nm (36.88 lb ft)
Page 31 V7 E5 Special-Stone Characteristics OOTRESTS Pos. Description Type Quantity Torque Notes Screws fastening rider footrest support to 25 Nm (18.44 lbf ft) Screw + nut the frame Screws fastening passenger footrest sup- 25 Nm (18.44 lbf ft) Pre-permeated port to the frame Anti-sliding pin 10 Nm (7.38 lbf ft)
Page 32 V7 E5 Special-Stone Characteristics EARBOX LEVER Pos. Description Type Quantity Torque Notes Gearbox lever fixing nut 25 Nm (18.44 lbf ft) Tie-rod fastening nuts 6.5 Nm (4.78 lbf ft) Gearbox control lever fastening 10 Nm (7.38 lbf ft) screws Gearbox lever peg fastener 20 Nm (14.75 lbf ft)
Page 33 V7 E5 Special-Stone Characteristics IDE STAND Pos. Description Type Quantity Torque Notes Side stand retainer pin M10x1.2 10 Nm (7.38 lbf ft) Lock nut for stand bolt M10x1.2 30 Nm (22.13 lb ft) Switch fixing screw M5x16 6 Nm (4.43 lbf ft)
Page 34 V7 E5 Special-Stone 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 lbf ft) ILTER BOX Pos. Description Type Quantity...
Page 35 V7 E5 Special-Stone Characteristics 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 lbf ft) Side panel fastening screws 4 Nm (2.95 lb ft)
Page 36 V7 E5 Special-Stone 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 lbf ft) Pre-permeated Saddle release block fixing screws 8 Nm (5.9 lb ft)
Page 37 V7 E5 Special-Stone Characteristics SYSTEM Pos. Description Type Quantity Torque Notes Control unit bracket fastening to the M6x16 10 Nm (7.38 lbf ft) frame Screw fastening brake lines fasten- 3 Nm (2.21 lbf ft) ing plates Clamp fastening screw 6 Nm (4.43 lbf ft)
Page 38 V7 E5 Special-Stone Characteristics WINGARM Pos. Description Type Quantity Torque Notes Pins fixing swingarm to gearbox Manual Counter-nuts fixing swingarm to 50 Nm (36.88 lb ft) gearbox Rubber bellows torx fixing screws 6 Nm (4.43 lbf ft) EVEL GEAR Pos.
Page 39 V7 E5 Special-Stone Characteristics EAR SHOCK ABSORBERS Pos. Description Type Quantity Torque Notes Rear shock absorber upper/lower fixing 10 Nm (7.38 lbf ft) Pre-permeated screws Pin fastening the shock absorber to the gear- 35 Nm (25.81 lb ft) Pre-permeated box/swingarm...
Page 40 V7 E5 Special-Stone Characteristics EAR BRAKE CALLIPER Pos. Description Type Quantity Torque Notes Rear brake calliper fixing screw 25 Nm (18.44 lbf ft) Screw fastening the calliper holder M16x1 35 Nm (25.81 lb ft) plate to the swingarm (SPECIAL) (STONE)
Page 41 V7 E5 Special-Stone Characteristics EAR WHEEL Pos. Description Type Quantity Torque Notes Rear brake disc fastening screws 25 Nm (18.44 lbf ft) Loctite 243 Rear wheel axle fastener pin + nut 100 Nm (73.77 lb ft) ABS sensor fixing screw 6 Nm (4.43 lbf ft)
Page 42 V7 E5 Special-Stone Characteristics EAR MUDGUARD Pos. Description Type Quantity Torque Notes Rear mudguard fixing screws 20 Nm (14.75 lbf ft) Front and centre fastening screw rear mud- 8 Nm (5.9 lb ft) guard Rear splash guard fastening screws 10 Nm (7.38 lbf ft)
Page 43 V7 E5 Special-Stone 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 lbf ft)
Page 44 V7 E5 Special-Stone Characteristics ENTRAL ELECTRICAL SYSTEM Pos. Description Type Quantity Torque Notes Coils fastening nuts 10 Nm (7.38 lbf ft) Starter motor fixing screws 25 Nm (18.44 lbf ft) EAR ELECTRICAL SYSTEM Pos. Description Type Quantity Torque Notes Control unit cable grommet fastening screw 3 Nm (2.21 lbf ft)
Page 45 INDEX OF TOPICS S-TOOLS PECIAL TOOLS...
Page 46 V7 E5 Special-Stone Special tools SPECIAL TOOLS Stores code Description 020998Y Pinion case wrench 020999Y Crown counter- lock ring wrench GU19907000 Internal bearing ring extractor 021000Y Bevel gear set mounting 021003Y Bevel gear oil seal punch 021005Y Bevel gear cover oil seal punch...
Page 47 V7 E5 Special-Stone Special tools Stores code Description 020978Y Cardan secondary oil seal mounting punch GU19927900 Punch for pressing the ring inside the bearing 020376Y Adaptor handle 020360S Adaptor 52x54 mm 001467Y036 Bearing internal cup extractor 020966Y Steering adjustment socket...
Page 48 V7 E5 Special-Stone Special tools Stores code Description 021017Y OBD cable for E5 vehicles Special tools are necessary for the correct removal and refitting and a good set-up. By using these special tools damages deriving from the use of incorrect tools and/or improvised operations will be avoided. Here is a list of the special tools suitably designed for this vehicle.
Page 49 V7 E5 Special-Stone Special tools Stores code Description 19.92.75.00 Extractor for external ring of gearcase bearing 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...
Page 50 INDEX OF TOPICS MAIN AINTENANCE...
Page 51 V7 E5 Special-Stone Maintenance Scheduled maintenance table NOTE HALVE THE SERVICE INTERVALS INDICATED IF THE VEHICLE IS USED IN PARTICULARLY RAINY OR DUSTY CONDITIONS, ON POOR ROADS OR FOR HIGH PERFORMANCE RIDING. NOTE THE TIMES LISTED ON THE SCHEDULED MAINTENANCE TABLE INCLUDE TIME DEDICATED TO MANAGEMENT ACTIVITIES.
Page 52 V7 E5 Special-Stone Maintenance Km x 1,000 (mi x 1,000) EVERY EVERY (0.9) (6.2) (12.4) (18.6) (24.9) (31.1) (37.3) MONTH MONTH Headlight aiming Fork oil seals (1) Tyres - pressure / wear (3) Clutch clearance adjustment Transmission oil filler plug washer...
Page 53 V7 E5 Special-Stone Maintenance mi x 1.000 (Km x 1.000) 0.9 (1.5) 6.2 (10) 12.4 (20) 18.6 (30) 24.9 (40) 31.1 (50) 37.3 (60) Head cover gasket Gearbox oil discharge plug aluminium gasket Engine oil discharge plug aluminium gasket Transmission oil discharge plug gasket...
Page 54 V7 E5 Special-Stone Maintenance Replacement CAUTION THE UNIT MUST BE HOT WHEN THE OIL IS CHANGED AS UNDER SUCH CONDITIONS OIL IS FLUID AND THEREFORE EASY TO DRAIN. NOTE RIDE SOME km (miles) TO WARM UP ENGINE OIL • Place a recipient with a capacity of at least 400 cc (25 cu.in) under the drain...
Page 55 V7 E5 Special-Stone Maintenance CAUTION IF IT IS NECESSARY TO INSTALL A NEW TRANSMISSION GEARBOX, PAY SPECIAL ATTEN- TION TO THE PROCEDURE BELOW Since they are already run-in at the factory, the complete transmission boxes coming from the Spare parts department contain a minimum residual oil quantity and therefore after installing them on the vehicle, the following procedure must be performed: •...
Page 56 V7 E5 Special-Stone Maintenance Replacement NOTE HOT OIL IS MORE FLUID AND WILL DRAIN OUT MORE EASILY AND COMPLETELY. • Posizionare un contenitore con capac- ità di raccolta adeguata in corrispon- denza del tappo di scarico (1) • Svitare e togliere il tappo di scarico (1) NOTE WHILE REFITTING, USE A NEW SEAL WASHER.
Page 57 V7 E5 Special-Stone Maintenance Engine oil filter • Undo the two screws (1) and remove the cover (2) • Remove the engine oil filter (3) • Spread a thin layer of oil on the sealing ring of the new engine oil filter •...
Page 58 V7 E5 Special-Stone Maintenance • Remove the air filter (3) and clean it • Check the O-Ring (4) and if necessary replace it • Screw and tighten the drainage plug • Pour in new oil, observing the quantity indicated in the table "capacity"...
Page 59 V7 E5 Special-Stone Maintenance • 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 • Loosen the clamps that secure the sleeve to the intake manifolds •...
Page 60 V7 E5 Special-Stone Maintenance • Remove the battery • Remove the MIU G4 control unit con- nector support bracket fixing screw • Disconnect the MIU G4 control unit connector • Remove the clip clamp fixing the throt- tle body to the filter box •...
Page 61 V7 E5 Special-Stone Maintenance • Loosen the gas cables fixing nuts on the throttle body and unhook them • Remove the throttle body Air filter housing ILTER BOX Pos. Description Type Quantity Torque Notes Filter box fastening screws SWP M5 3 Nm (2.21 lbf ft)
Page 62 V7 E5 Special-Stone Maintenance Pos. Description Type Quantity Torque Notes Filter casing/frame fastening screw SWP M5 3 Nm (2.21 lbf ft) Air filter housing removal • Remove the saddle and the side fair- ings • Remove the battery • Remove the rear wheel.
Page 63 V7 E5 Special-Stone Maintenance • Unscrew the clamp that fastens the throttle body to the air filter box • Disconnect the blow-by pipe • Remove the air-box cover • Remove sliding the complete filter box out toward the rear MAIN - 63...
Page 64 V7 E5 Special-Stone Maintenance Air filter housing installation • Insert the filter box from the rear • 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.
Page 65 V7 E5 Special-Stone Maintenance • Position the air filter box support, tak- ing car to pass the neutral switch ca- bling through the hole • 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.
Page 66 V7 E5 Special-Stone Maintenance Checking the valve clearance • First, check the valve clearance in the left cylinder, then remove the four fixing screws (1) on the spark plug cover (2) • Remove the spark plug cover (2) • Disconnect the spark plug cap (3) •...
Page 67 V7 E5 Special-Stone Maintenance • Retrieve the two spacers (5) • Push the spark plug cable complete with support, as indicated in the figure, towards the front of the vehicle • Unscrew and remove the three head cover retaining screws (6) •...
Page 68 V7 E5 Special-Stone Maintenance • Use a feeler gauge to check that the clearance between the valve and the set screw corresponds with the indica- ted values. The corresponding intake and outlet valve clearances are differ- ent than what is indicated below, pro- ceed with adjusting them.
Page 69 V7 E5 Special-Stone Maintenance RONT BRAKE CALLIPER Pos. Description Type Quantity Torque Notes Screws fastening front brake calliper 50 Nm (36.88 lb ft) RONT BRAKE MASTER CYLINDER Pos. Description Type Quantity Torque Notes Front brake master cylinder U-bolt fixing 10 Nm (7.38 lbf ft)
Page 70 V7 E5 Special-Stone Maintenance EAR BRAKE CALLIPER Pos. Description Type Quantity Torque Notes Rear brake calliper fixing screw 25 Nm (18.44 lbf ft) Screw fastening the calliper holder M16x1 35 Nm (25.81 lb ft) plate to the swingarm EAR BRAKE PUMP Pos.
Page 71 V7 E5 Special-Stone 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...
Page 72 V7 E5 Special-Stone 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 73 V7 E5 Special-Stone Maintenance • Remove the brake fluid reservoir cover • Remove the inner cover (3) • Remove the diaphragm (4) • Top up the brake fluid reservoir MAIN - 73...
Page 74 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 75 V7 E5 Special-Stone Electrical system RONT ELECTRICAL SYSTEM Pos. Description Type Quantity Torque Notes Voltage regulator and horn fastening screws 10 Nm (7.38 lbf ft) Clutch switch fixing screw 5 Nm (3.69 lb ft) ENTRAL ELECTRICAL SYSTEM Pos. Description Type...
Page 76 V7 E5 Special-Stone Electrical system EAR ELECTRICAL SYSTEM Pos. Description Type Quantity Torque Notes Control unit cable grommet fastening screw 3 Nm (2.21 lbf ft) Thread-form- ing screws Battery holder bracket fastening screws Manual Fuse box bracket fastening screws 4 Nm (2.95 lb ft)
Page 77 V7 E5 Special-Stone Electrical system Components arrangement Key: 1. Instrument cluster 2. Coil 3. Fuel pump 4. Injector ELE SYS - 77...
Page 78 V7 E5 Special-Stone Electrical system 5. Taillight 6. MIU G4 control unit 7. Engine speed sensor 8. Starter motor 9. Engine speed sensor 10.Fuses 11.Battery 12.Head temperature sensor 13.Instrument cluster air sensor 14.Headlamp 15.Voltage regulator 16.Alternator 17.Oil pressure sensor 18.Lambda probes...
Page 79 V7 E5 Special-Stone Electrical system • 1 Black sheath • 7 ABS Cable grommets • 1 connector clip Motorcycle division The wiring harnesses on the vehicle are subdivi- ded into three main sections, as indicated in the figure. 1. Front of vehicle 2.
Page 80 V7 E5 Special-Stone Electrical system • Check correct insertion of the starter motor hood and engine start faston • Check the presence of the Red protective hood on the battery Positive • Check that the stand switch connector is blue •...
Page 81 V7 E5 Special-Stone Electrical system TABLE C - CONDUIT • Check that the fall sensor arrow is up- wards and that the connector is grey • Place a large clamp so that the sensor cable is positioned as indicated •...
Page 82 V7 E5 Special-Stone 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)
Page 83 V7 E5 Special-Stone Electrical system • Pass the ABS sensor wiring harness around the steering headstock through the metal cable grommet (4) on the chassis and then fasten it with 2 plastic clamps in the dedicated seat on the conduit.
Page 84 V7 E5 Special-Stone Electrical system TABLE B1 • Check that the front stop fastons are well fastened, by slightly pulling them TABLE B2 - LIGHT SWITCH CABLE PASSAGE ON THE HANDLEBAR (SPECIAL) • Fasten the RH light switch wiring har-...
Page 85 V7 E5 Special-Stone Electrical system TABLE C - INSTRUMENT CLUSTER 1. Connector support bracket 2. Air temperature sensor connector 3. Connector support 4. Large clamp • The large sized clamp fastens the air temperature sensor connector and the main branch of the instrument cluster...
Page 86 V7 E5 Special-Stone Electrical system TABLE C4 - INSTRUMENT CLUSTER (SPE- CIAL) • Once fully assembled, the instrument cluster appears as shown in the figure TABLE D - CABLE RUN ON THE STEERING HEADSTOCK 1. Medium sized clamp 2. Small sized clamps •...
Page 87 V7 E5 Special-Stone Electrical system TABLE E - INSTRUMENT CLUSTER AND FRONT ARROWS (STONE) • Proceed as indicated in the figure: us- ing a small clamp, fasten both arrow wiring harnesses to the instrument cluster, next to the red strip on the left...
Page 88 V7 E5 Special-Stone Electrical system TABLE F1 • Pass the clutch cable wiring harness through the metal cable grommet on the chassis, fasten it with a large plastic clamp to the wiring harnesses along the steering headstock and hide the...
Page 89 V7 E5 Special-Stone Electrical system Central part TABLE A - CONDUIT ON THE FRAME • Check that the relays are well inserted. The quantities vary depending on the models: Special 3 relays - Stone 2 re- lays • Fasten the lower part of the conduit us-...
Page 90 V7 E5 Special-Stone Electrical system TABLE A2 • Voltage regulator connector (1) • RH light switch connector (2) • LH light switch connector (3) • RH Lambda probe connector (4) • Front ABS sensor connector (5) TABLE A3 • Heated handgrips provision (1) •...
Page 91 V7 E5 Special-Stone 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 92 V7 E5 Special-Stone 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 93 V7 E5 Special-Stone Electrical system TABLE D5 • Fit the bracket (1) that connects the ECU to the associated support using the three fixing screws (2) TABLE E - RH LAMBDA SENSOR • Pass the wiring harness between the brake pipes and the chassis and then...
Page 94 V7 E5 Special-Stone Electrical system TABLE F - LEFT LAMBDA PROBE • Connect the wiring harness to the con- nector (1) fastened to the chassis TABLE G - HORN AND REGULATOR 1. Voltage regulator 2. Horn • The regulator's cable must pass be-...
Page 95 V7 E5 Special-Stone Electrical system TABLE G1 • Check the connection of the flywheel white connector and regulator's black connector that must have a safety clamp to avoid disconnection • Once connected, the connectors must be placed behind the steering head- stock plates and above the main wiring harness conduit.
Page 96 V7 E5 Special-Stone Electrical system TABLE H - FLYWHEEL CABLES PASSAGE • Using a medium clamp, fasten the fly- wheel cable and the regulator cable to the voltage regulator support bracket TABLE I - NEUTRAL SENSOR CABLES PAS- SAGE •...
Page 97 V7 E5 Special-Stone Electrical system TABLE I2 • Connect the neutral sensor cable to the associated connector on the vehicle. Using a small clamp, fasten the cable to the rear cables of the ABS and Stop sensor TABLE A - OIL PRESSURE SENSOR •...
Page 98 V7 E5 Special-Stone Electrical system TABLE A - OIL PRESSURE SENSOR • Connect the cable to the oil pressure sensor (1) and orient it as shown in the picture • Pass the sensor cable behind the brake pipes and then fasten the cable...
Page 99 V7 E5 Special-Stone Electrical system TABLE L - SECONDARY AIR VALVE • Check the correct connection of the secondary air valve sensor (1) and then apply the protective cap on the connector TABLE M - ANTI-THEFT FITTING • Check the correct connection of the ig-...
Page 100 V7 E5 Special-Stone Electrical system TABLE O - REAR STOP SWITCH WIRING HAR- NESS PASSAGE • Pass the wiring harness under the brake pipe coupling, behind the pump and then insert it between the chassis and the gearbox • Fasten the wiring harness to the cable...
Page 101 V7 E5 Special-Stone Electrical system 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 • Check the tightening to the prescribed torque TABLE Q - SIDE STAND SENSOR •...
Page 102 V7 E5 Special-Stone Electrical system TABLE Q2 • Proceed as shown in the figure, mak- ing sure to pass the switch wiring har- ness behind the MIU G4 ECU TABLE Q3 • Using a plastic clamp, fasten the wiring harness to the canister valve pipe and...
Page 103 V7 E5 Special-Stone 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...
Page 104 V7 E5 Special-Stone Electrical system INCORRECT SECURING OF THIS COMPONENT MAY CAUSE THE VEHICLE TO CATCH FIRE TABLE T1 • The starter motor cable must pass un- der the filter box pipe TABLE T2 • Check that the starter positive cap is...
Page 105 V7 E5 Special-Stone Electrical system TABLE U - OBD 2 PORT • Insert the plug (1) in the OBD 2 port and then insert the port in the associ- ated rubber support, located next to the fuse box TABLE V - USB PORT FITTING •...
Page 106 V7 E5 Special-Stone Electrical system TABLE X - MIU G4 ECU • The MIU G4 ECU wiring harness branch must be placed as shown in the figure • Make sure that the connector's rubber protection is well fitted TABLE X1 •...
Page 107 V7 E5 Special-Stone Electrical system TABLE Y - CANISTER VALVE • Proceed as indicated in the figure • Make sure that the canister valve is positioned as in the figure so as to have the connection perpendicular to the support bracket...
Page 108 V7 E5 Special-Stone Electrical system TABLE A1 • Using the two small clamps, fasten the ABS sensor cable to the rear brake pipe • Pass the cable through the space be- tween the gearbox and the swingarm, next to the cardan shaft output TABLE A2 •...
Page 109 V7 E5 Special-Stone Electrical system TABLE B - TAILLIGHTS AND REAR ARROWS • Fasten the wiring harness through the cable grommet (1), next to the grey ref- erence mark on it • Connect the connectors of the follow- ing: taillight (2), left arrow (3) and right...
Page 110 V7 E5 Special-Stone Electrical system TABLE C - LICENSE PLATE LIGHT • Install the licence plate light on the plate holder TABLE D - REAR MUDGUARD PRE-FITTING • Fit the taillight on the mudguard, mak- ing sure to apply the cable grommet...
Page 111 V7 E5 Special-Stone Electrical system TABLE D3 • Spread the cable as shown in the fig- ure, making sure to insert it in the spe- cific places inside the mudguard • Fit the screws (4) and the washer until the end, to prevent the cable from be-...
Page 112 V7 E5 Special-Stone Electrical system Key: 1. Multiple connectors 2. air temperature sensor 3. Instrument cluster 4. Instrument cluster 5. Lights relay 6. Starter motor relay ELE SYS - 112...
Page 113 V7 E5 Special-Stone Electrical system 7. Clutch switch 8. Right light switch 9. Front stop switch 10.Horn 11.Left light switch 12.USB socket (where applicable) 13.Brake light switch 14.Ignition switch 15.Rear right turn indicator (LED) 16.Taillight (LED) 17.Licence plate light (LED) 18.Rear left turn indicator (LED)
Page 114 V7 E5 Special-Stone Electrical system 45.Pick-up 46.Engine head temperature sensor 47.Fall sensor 48.MIU G4 control unit 49.GMP (if fitted) 50.Secondary air system 51.OBD connector 52.Front left turn indicator (LED) 53.Headlight 54.High/low beam bulb 55.Front daylight running light bulb 56.- 57.Front right turn indicator (LED) 58.Heated handgrips switch (if fitted)
Page 115 V7 E5 Special-Stone Electrical system Key: 1. Multiple connectors 2. air temperature sensor 3. - 4. Instrument cluster 5. - 6. Starter motor relay ELE SYS - 115...
Page 116 V7 E5 Special-Stone Electrical system 7. Clutch switch 8. Right light switch 9. Front stop switch 10.Horn 11.Left light switch 12.USB socket (where applicable) 13.Brake light switch 14.Ignition switch 15.Rear right turn indicator (LED) 16.Taillight (LED) 17.Licence plate light (LED) 18.Rear left turn indicator (LED)
Page 117 V7 E5 Special-Stone Electrical system 45.Pick-up 46.Engine head temperature sensor 47.Fall sensor 48.MIU G4 control unit 49.GMP (if fitted) 50.Secondary air system 51.OBD connector 52.Front left turn indicator (LED) 53.Headlight 54.High beam light LED 55.Low beam light LED 56.Position/DRL LED 57.Front right turn indicator (LED)
Page 118 V7 E5 Special-Stone Electrical system Maintenance icon reset The system displays the function as follows: • After the maintenance interval thresh- olds are exceeded (excepting the first), an icon with the adjustable wrench is shown on the digital display. To reset Service proceed as follows: •...
Page 119 V7 E5 Special-Stone 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 120 V7 E5 Special-Stone 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 121 V7 E5 Special-Stone 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 122 V7 E5 Special-Stone 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 123 V7 E5 Special-Stone Electrical system BULBS (STONE) Specification Desc./Quantity High beam/low beam light Front DRL taillight /stop lights Turn indicators Dashboard lighting Fuses (HALOGEN) FUSE DISTRIBUTION 1. Main fuse, coil 1 and 2, fuel pump, injectors 1 and 2, lambda 1 and 2. (30 A).
Page 124 V7 E5 Special-Stone Electrical system 6. Low beam/high beam lights, passing, DRL/ position lights, stop, horn. (10 A). ABS FUSE LAYOUT 1. ABS ECU (20 A). 2. Spare fuse (20 A). Battery Function Provide electrical supply, the battery is YUASA.
Page 125 V7 E5 Special-Stone Electrical system • If too high: too high a voltage has been detected at PIN 9. If too low: too low a voltage has been detected at PIN 9. The instrument panel does not indicate the presence of this error even in the ATT status.
Page 126 V7 E5 Special-Stone Electrical system • Electrically defective wiring or sensor Troubleshooting • Check the sensor connector and the ABS control unit connector. If they are not OK, restore the connectors. If they are OK, check continuity of the white/brown cable between PIN 2 of the sensor on the wiring harness side and PIN 14 of the ABS control unit connector If there is no continuity, restore them.
Page 127 V7 E5 Special-Stone Electrical system • 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; If it is not OK, restore it. If it is, check if the tone wheel has the correct number of teeth or if it is dirty, deformed or wrongly fixed;...
Page 128 V7 E5 Special-Stone Electrical system • On the swingarm, left side, on the rear brake calliper support plate Pin-out 1. Earth (Yellow) 2. Power supply voltage/Output signal (yellow/ brown) Diagnostic tool - Parameters and statuses • Vehicle speed - (km/h) •...
Page 129 V7 E5 Special-Stone 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 130 V7 E5 Special-Stone Electrical system Engine rpm sensor Function It informs crankshaft position and speed to the Marelli control unit Operation / Operating principle Inductive sensor: sinusoidal-type generated volt- age; two teeth are missing on the flywheel for the reference position...
Page 131 V7 E5 Special-Stone Electrical system • An interruption in the sensor circuit has been detected, from PIN 20 to PIN 29 of the control unit connector. • Check the sensor connector and the injection ECU connector: If the values are incorrect restore them.
Page 132 V7 E5 Special-Stone Electrical system • Resistance at 80°C: 0.377 kΩ ± 5% • Resistance at 100°C: 0.204 kΩ ± 5% Pin-out • 0-5 V signal (grey wiring harness side) • Ground (blue/green wiring harness side) Diagnostic tool - Parameters and statuses •...
Page 133 V7 E5 Special-Stone Electrical system • If PIN 2 is insulated from the ground and the error persists, this means that there is a probable fault in the control unit. Lambda sensor Function In charge of telling the control unit whether the...
Page 134 V7 E5 Special-Stone Electrical system Diagnostic tool - Activation • Lambda probe heater 2 Diagnostic tool - Electrical errors Control of the air-fuel ratio / Right lambda probe P0150 - positive short circuit / open circuit, short circuit to negative / signal not valid.
Page 135 V7 E5 Special-Stone Electrical system • Disconnect the control unit connector and the sensor connector. • Verify that there is no short to battery positive on sensor connector PIN 3 (corresponding to control unit connector PIN 2); if there is a short, restore the wiring harness.
Page 136 V7 E5 Special-Stone Electrical system Not active (rich), Operating, Not active (lean), Fault Diagnostic tool - Activation • Lambda probe heater 1 Diagnostic tool - Electrical errors Control of the air-fuel ratio / Left lambda probe P0130 - positive short circuit / open circuit, short circuit to negative / signal not valid.
Page 137 V7 E5 Special-Stone Electrical system • Open circuit: circuit interruption. Troubleshooting Short-circuit to positive: • Disconnect the control unit connector and the sensor connector. • Verify that there is no short to battery positive on sensor connector PIN 3 (corresponding to control unit connector PIN 31);...
Page 138 V7 E5 Special-Stone Electrical system 1. Power 12V (red/brown) 2. Ground (grey/red) Diagnostic tool - Parameters and statuses • Injection time cyl. RH - (ms) Diagnostic tool - Activation • Right injector • Injector control Diagnostic tool - Electrical errors Front injector P0202 - shorted to positive / shorted to negative / open circuit.
Page 139 V7 E5 Special-Stone Electrical system Electrical specifications • 14.8 Ohm +/- 5% (at 20 °C - 68 °F) Pin-out: 1. Power 12V (red/brown) 2. Ground (grey/black) Diagnostic tool - Parameters and statuses • Injection time cyl. LH - (ms) Diagnostic tool - Activation •...
Page 140 V7 E5 Special-Stone Electrical system Fuel pump Function Fuel pump: keeps pressure of the injectors supply duct. Low fuel: tells to the instrument panel about low fuel Operation / Operating principle The fuel reserve is a resistance that if correctly...
Page 141 V7 E5 Special-Stone Electrical system • Circuit interruption. Troubleshooting Short-circuit to positive: • Disconnect the injection loads relay (No. 28 on the electrical circuit diagram), turn the key to the ON position and activate the injection loads relay through the diagnostic tool.
Page 142 V7 E5 Special-Stone Electrical system • Secondary winding resistance: 3 kΩ ± • Tube resistance 5 kΏ Pin-out 1. Circuit ground (orange/white) 2. Power supply (red/brown) Diagnostic tool - Activation • Left coil • Coil command Diagnostic tool - Electrical errors H.V.
Page 143 V7 E5 Special-Stone Electrical system RIGHT COIL Level in electrical circuit diagram Coil 2 (right cylinder) Position • Centred under the fuel tank. • Connector: on the coil. Electrical specifications • Primary winding resistance: 550 kΩ ± • Secondary winding resistance: 3 kΩ ±...
Page 144 V7 E5 Special-Stone Electrical system • Verify, with the key turned ON, the presence of voltage on the right coil connector PIN 1. If no voltage is read, verify the continuity of the wiring harness between right coil and injection loads relay (No.
Page 145 V7 E5 Special-Stone Electrical system • Possible malfunction Troubleshooting • Carry out the check procedure on the green/black sensor/control unit cable. • Restore if damaged. • If OK, with the transmission in neutral, check for continuity to ground of the sensor connector.
Page 146 V7 E5 Special-Stone Electrical system • Clutch pulled: closed circuit (continui- • Clutch released: open circuit (infinite resistance) Pin-out 1. 12 V Voltage (brown/white) 2. Ground (blue/green) Diagnostic tool - Parameters and statuses • Clutch - (Pulled, Released) Diagnosis Even with the clutch lever pulled, the vehicle does not start Error cause •...
Page 147 V7 E5 Special-Stone Electrical system Side stand sensor Function Indicates the side stand position to the control unit Operation / Operating principle If the gear is engaged and the side stand is unfol- ded, and therefore the circuit is open, the control...
Page 148 V7 E5 Special-Stone Electrical system • Possible malfunction Troubleshooting • disconnect the sensor connector and check that, with side stand extended, there is not continuity between the two PINS. • If present, replace the sensor. If absent, disconnect from control unit PIN 19 and check insulation from the ground of the grey/yellow cable between sensor and control unit.
Page 149 V7 E5 Special-Stone Electrical system • Possible malfunction caused by the fall sensor or RUN-STOP switch Troubleshooting • See diagnosis "RUN-STOP switch", if not ok check the correct status of the fall sensor SAS valve actuator Function Improves the reaction of oxide, reduction after...
Page 150 V7 E5 Special-Stone Electrical system • Possible malfunction Troubleshooting • Disconnect the connector and check the resistance between PIN of the valve connector; if the resistance value is close to 10-20 Ω the valve is ok, if the value of the resistance is equal to 0 it can be said that there is a short circuit on the valve, instead if there is a resistance equal to a ∞...
Page 151 V7 E5 Special-Stone Electrical system • Sensor: right light switch • Connector: next to the headstock, right side Electrical specifications • STOP position: open circuit • RUN position: closed circuit (continui- Pin-out 1. Voltage 0 V with engine kill in STOP; 12V if engine kill in RUN (pink/yellow cable) 2.
Page 152 V7 E5 Special-Stone Electrical system Connectors Function It manages injection/ignition, the system safety checks and the self-diagnosis function. The con- trol unit is Magneti Marelli MIU G4 Level in electrical circuit diagram Secondary air system Bluedash pre-installation Antitheft device ABS system...
Page 153 V7 E5 Special-Stone Electrical system Pin-out 1. Left coil command output (1) 2. Right Lambda heater command output (2) 3. - 4. Run-off control input 5. Start button inlet 6. Ignition switch positive 7. Ground 1 (-) 8. Right coil command output (2) 9.
Page 154 V7 E5 Special-Stone Electrical system 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 • ISO code •...
Page 155 V7 E5 Special-Stone Electrical system • Corr. title cylinder RH - (%) • Corr. title carb. cyl. LH - (%) • Corr. title carb. cyl. RH - (%) • Steps carried out - (step) • Programmed steps - (step) •...
Page 156 V7 E5 Special-Stone Electrical system ation, Deceleration, Cut-off, Restore Cut-off) • Throttle valve status - (---, Minimum, Full power, partial position) • Engine status - (Undetermined, Po- wON/Engine off, KeyON/engine off, Rotation, Engine Stall, Pwr latch in pro- gress, Pow.Latch Term, Stop, Syn- chronis.
Page 157 V7 E5 Special-Stone Electrical system • Unlock with gas - (NO, YES) • Key or antenna faulty - (NO, YES) • Wrong code - (NO, YES) • Communication timeout - (NO, YES) CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING...
Page 158 V7 E5 Special-Stone Electrical system Diagnostic tool - Adjustment This screen page is used to adjust some control unit parameters • Resetting • Downloading Mem Data • Self-adaptive parameters reset Diagnostic tool - Electrical errors Air pressure sensor P0105 - short circuit to positive / open circuit, short circuit to negative, signal not...
Page 159 V7 E5 Special-Stone Electrical system • The instrument cluster does not indicate the presence of this error even in the ATT status Troubleshooting • Replace the engine control unit Error ROM P0605 - circuit not working Error cause • The instrument cluster does not indicate the presence of this error even in the ATT status Troubleshooting •...
Page 160 V7 E5 Special-Stone Electrical system Dashboard PIN: 1. CAN H line 2. High beam warning light inlet 3. Engine oil pressure sensor inlet 4. / 5. ABS Warning light control inlet 6. Ground lead 7. Ground lead 8. CAN L line 9.
Page 161 V7 E5 Special-Stone Electrical system • General alarm warning continuously on (red) and indication "ALARM DISCONNECTED" on the display Troubleshooting • Check the integrity and the continuity of the cables of the CAN line between PIN 8 instrument cluster and PIN 27 injection control unit and between PIN 1 instrument cluster and PIN 26 injection control unit •...
Page 162 V7 E5 Special-Stone 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 163 V7 E5 Special-Stone 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 164 V7 E5 Special-Stone Electrical system 2. Ground (brown) Diagnosis An instrument cluster 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 165 V7 E5 Special-Stone 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 166 V7 E5 Special-Stone 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 167 V7 E5 Special-Stone 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 168 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 169 V7 E5 Special-Stone Engine from vehicle RAME Pos. Description Type Quantity Torque Notes Screws fastening the tank support 25 Nm (18.44 lbf ft) buffers to the frame Front cradle fixing screws 50 Nm (36.88 lb ft) Pre-permeated Screw fastening the stand cross- 50 Nm (36.88 lb ft)
Page 170 V7 E5 Special-Stone 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 • Disconnect the cylinder temperature sensor connector.
Page 171 V7 E5 Special-Stone Engine from vehicle • Remove the silencer guard, sliding it toward the front of the vehicle • Loosen the clamp between the silencer and manifold • Remove the screw that fastens the si- lencer to the support bracket •...
Page 172 V7 E5 Special-Stone Engine from vehicle • Remove the two starter motor cover fixing screws • Remove the starter motor cover • Disconnect from their support the con- nectors of the lambda probe wiring har- ness. • Using a screwdriver, press the tab and...
Page 173 V7 E5 Special-Stone 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 174 V7 E5 Special-Stone Engine from vehicle • Disconnect the spark plugs tubes • Remove the screws fixing the manifold to the cylinder heads • Remove the fixing screw of the engine oil pressure sensor cover • Remove the engine oil pressure sen- sor cover •...
Page 175 V7 E5 Special-Stone Engine from vehicle • Remove the fixing nut of the engine ground cable • Remove the fixing nut of the power supply cable located on the starter mo- tor. Then remove the cable • Disconnect the starter motor faston •...
Page 176 V7 E5 Special-Stone Engine from vehicle • Remove the starter motor complete with support bracket for the cover • Disconnect the secondary air system pipes from the cylinder heads • Remove the clamp fixing the flywheel wiring harness to the brake pipes •...
Page 177 V7 E5 Special-Stone Engine from vehicle • Disconnect the flywheel/alternator connectors and release them from the passage in the frame • Remove the fixing screws of the rider right footrest / rear brake pump assem- • Remove the rider right footrest / rear...
Page 178 V7 E5 Special-Stone Engine from vehicle • Disconnect the side stand sensor con- nector and then remove the wiring har- ness from the lower side of the vehicle • Disconnect the uniball that connects the gear lever transmission to the ve- hicle's gearbox •...
Page 179 V7 E5 Special-Stone Engine from vehicle • Remove the clamp and disconnect the pipe that connects the valve to the can- ister. Remove the pipe by extracting it from the lower side of the vehicle • Remove the cradle lower fixing screw •...
Page 180 V7 E5 Special-Stone Engine from vehicle • Remove the cradle from the vehicle's chassis together with the canister and the left footrest/gear lever assembly • Remove the rear brake calliper and the ABS sensor • Remove the cable grommet plate placed under the swingarm •...
Page 181 V7 E5 Special-Stone Engine from vehicle • Secure the chassis on a lifting device and place a pantograph stand under the oil sump • Remove the pins fastening the gear- box to the chassis, making sure to re- trieve the associated nuts and washers •...
Page 182 V7 E5 Special-Stone Engine from vehicle • Disconnect the gear sensor connector • Lift the frame sufficiently and remove the engine complete with swingarm ENG VE - 182...
Page 183 INDEX OF TOPICS NGINE...
Page 184 V7 E5 Special-Stone Engine TO CONSULT THE CHAPTER ABOUT THE ENGINE AND ITS COMPONENTS PLEASE REFER TO THE APPROPRIATE MANUAL: "MSS Engine 850 Euro 5" ENG - 184...
Page 185 INDEX OF TOPICS P SUPP OWER SUPPLY...
Page 186 V7 E5 Special-Stone 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 - 186...
Page 187 V7 E5 Special-Stone Power supply Diagram Key: 1. Control unit position 2. Ignition switch 3. Battery 4. Fuel pump 5. Coils 6. Instrument cluster 7. air temperature sensor 8. Throttle valve position sensor 9. Injectors 10.Engine temperature sensor 11.Lambda probe 12.Side stand switch...
Page 188 V7 E5 Special-Stone Power supply 13.Gear sensor 14.fall sensor P SUPP - 188...
Page 189 INDEX OF TOPICS SUSP USPENSIONS...
Page 190 V7 E5 Special-Stone 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 lbf ft) Mirror fixing Manual Light switch fastening screws SWP 5 1.5 Nm (1.11 lb ft)
Page 191 V7 E5 Special-Stone Suspensions Front fork RONT SUSPENSION TEERING Pos. Description Type Quantity Torque Notes Screws fastening stanchion on upper plate M8x35 25 Nm (18.44 lbf 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...
Page 192 V7 E5 Special-Stone Suspensions Pos. Description Type Quantity Torque Notes Connector plate fastening screw M6x16 10 Nm (7.38 lbf ft) Screws fastening stanchion on lower plate 45 Nm (33.19 lb ft) Pumping unit fastening screw 50 Nm (36.88 lb ft)
Page 193 V7 E5 Special-Stone 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 194 V7 E5 Special-Stone 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 195 V7 E5 Special-Stone 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 196 V7 E5 Special-Stone Suspensions • Slide the dust scraper off and upwards. • Remove the locking ring inside the fork leg using a thin screwdriver. CAUTION BE CAREFUL NOT TO DAMAGE THE FORK LEG RIM. • Slide off the bearing tube from the...
Page 197 V7 E5 Special-Stone 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 198 V7 E5 Special-Stone 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 199 V7 E5 Special-Stone 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 200 V7 E5 Special-Stone 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 - 200...
Page 201 V7 E5 Special-Stone Suspensions Steering bearing RONT SUSPENSION TEERING Pos. Description Type Quantity Torque Notes Screws fastening stanchion on upper plate M8x35 25 Nm (18.44 lbf 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...
Page 202 V7 E5 Special-Stone Suspensions Pos. Description Type Quantity Torque Notes Connector plate fastening screw M6x16 10 Nm (7.38 lbf 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 203 V7 E5 Special-Stone 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 204 V7 E5 Special-Stone Suspensions Shock absorbers EAR SHOCK ABSORBERS Pos. Description Type Quantity Torque Notes Rear shock absorber upper/lower fixing 10 Nm (7.38 lbf ft) Pre-permeated screws Pin fastening the shock absorber to the gear- 35 Nm (25.81 lb ft)
Page 205 V7 E5 Special-Stone Suspensions • Remove the RH rear shock absorber REAR LEFT SHOCK ABSORBER • Unscrew and remove the two screws • Retrieve the two bushings (2) • Remove the rear shock absorber (3) SUSP - 205...
Page 206 INDEX OF TOPICS CHAS HASSIS...
Page 207 V7 E5 Special-Stone Chassis Wheels Front wheel (SPECIAL) (STONE) CHAS - 207...
Page 208 V7 E5 Special-Stone Chassis 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 lbf ft) Loctite 243 ABS-sensor fixing stud bolt 6 Nm (4.43 lbf ft)
Page 209 V7 E5 Special-Stone Chassis • 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 210 V7 E5 Special-Stone Chassis (STONE) EAR WHEEL Pos. Description Type Quantity Torque Notes Rear brake disc fastening screws 25 Nm (18.44 lbf ft) Loctite 243 Rear wheel axle fastener pin + nut 100 Nm (73.77 lb ft) ABS sensor fixing screw 6 Nm (4.43 lbf ft)
Page 211 V7 E5 Special-Stone 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 fixing the left-hand rear shock absorber and remove it from the pin •...
Page 212 V7 E5 Special-Stone Chassis • Remove the rear brake calliper support • Collect the spacer NOTE DURING REFITTING, PAY ATTENTION TO THE CORRECT POSITIONING OF THE SPACER WHICH MUST BE INSER- TED IN THE DUST SEAL UNTIL IT REACHES THE BEAR- •...
Page 213 V7 E5 Special-Stone Chassis • Remove the dust seal • Remove the locking Seeger ring of the bearing from the side where the en- coder/brake disc wheel is present • Using a generic bearing extractor remove the bearings from both sides...
Page 214 V7 E5 Special-Stone Chassis • After having adjusted the tension of the wheel spokes, check the axial and radial clearance of the wheel rim. CAUTION DO NOT ADJUST THE TENSION OF THE WHEEL SPOKES WITH TIRES FITTED ON THE WHEEL RIM, AS THIS COULD CAUSE BREAKING OF THE NIPPLE GUARDS AND RESULTING IN HOLES OF THE AIR CHAMBER.
Page 215 V7 E5 Special-Stone Chassis Removing • Remove the mufflers, the rear wheel, and the brake calliper support com- plete with clamp / ABS sensor, and disconnect the shock absorbers from the support pins. • Remove the fixing nut of the cable...
Page 216 V7 E5 Special-Stone Chassis • Remove the complete swingarm from the gearbox • Remove the three screws (1) to re- move the folding (2) complete with re- taining ring (3) 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 217 V7 E5 Special-Stone Chassis Checking Carefully check: The splines on the cardan shaft (1) must be intact, free from grain or dents. Check that the joints (2) are not hardened or ex- cessively loose, otherwise replace it. In the figure are shown two worn toothing profiles: •...
Page 218 V7 E5 Special-Stone Chassis EVEL GEAR Pos. Description Type Quantity Torque Notes Pinion unit fixing nut - OPTION 01 100 Nm (73.76 lb ft) Loct. 243 Pinion unit fixing lock nut - OPTION 20 Nm (14.75 lbf ft) Loct. 243 Pinion unit fixing nut - OPTION 02 100 Nm (73.76 lb ft)
Page 219 V7 E5 Special-Stone Chassis • Remove the gearbox (3). Replacement of the oil seal on the wheel hub with bevel gear mounted on the vehicle • Firmly screw a small self-tapping screw (M5-M6) on the oil seal • Use a clamp to grab the screw and re-...
Page 220 V7 E5 Special-Stone Chassis • Insert a new oil seal in the specific seat, tap it inside with a tube with a slightly smaller diameter than the external di- ameter of the oil seal • The oil seal is inserted when it reaches...
Page 221 V7 E5 Special-Stone Chassis • Remove the ring gear axle thickness. • Remove the inner spacer. • Remove the bearing's roller cage. • Using a suitable tool, disengage the ra- dial snap ring and remove it. CHAS - 221...
Page 222 V7 E5 Special-Stone Chassis • Heat the outer track seat of the roller bearing using an air heater. • Insert the special tool under the washer and screw the cursor. Specific tooling 001467Y036 Bearing internal cup extractor • Insert a bush with a suitable diameter on the specific tool and tighten the nut keeping the extractor locked.
Page 223 V7 E5 Special-Stone Chassis • Remove the washer. • Remove the sealing ring. • When reassembling use a new ring. CAUTION DURING REASSEMBLY BE CAREFUL, AS THE SEALING RING MUST BE INSERTED UNTIL IT STOPS, USING THE SPECIFIC PRESS-FIT PAD.
Page 224 V7 E5 Special-Stone Chassis • Unscrew the ring nut, using the special tool, to loose the riveting. • After unscrewing the ring nut to the end of the thread, re-tighten it until it stops in such a way as to create the space between the ring nut and the shoulder washer.
Page 225 V7 E5 Special-Stone Chassis • Remove the ring nut. • Remove the crown gear. • Remove the gearbox flange from the splash guard hub. • Remove the O-ring. • When reassembling use a new O-ring. CAUTION PAY SPECIAL ATTENTION TO THE CORRECT REMOVAL PROCEDURE OF THE OIL SEAL TO AVOID THE DAMAGE OF THE STEEL SHEET UNDER THE OIL SEALER.
Page 226 V7 E5 Special-Stone Chassis • Use a small self-tapping screw (M5- M6) and screw it slightly to grip on the oil seal. CAUTION DO NOT TIGHTEN THE SCREW AS IT COULD DAMAGE THE UNDERLYING THIN SHEET. • Using a clamp to remove the oil seal...
Page 227 V7 E5 Special-Stone Chassis • Heat the outer area of the pinion bear- ings holder case • Using the special tool, loose and re- move the pinion bearings holder case. Specific tooling 020998Y Pinion case wrench • Using the specific tool, clamp the as- sembly in the vice and lift the nut again before removing it.
Page 228 V7 E5 Special-Stone Chassis • Remove the sealing ring. • Remove the O-ring. Checking • Dopo il montaggio della scatola, è necessario verificare il gioco tra pignone e corona. Bloc- care in morsa il pignone e installare un comparatore mediante un supporto idoneo. Il tastatore del comparatore deve appoggiarsi all'estremità...
Page 229 V7 E5 Special-Stone Chassis Assembling • Insert the new internal O-ring in the pinion unit. • Insert a new seal ring until it stops • Insert the bearings closing spacer pay- ing attention that the chamfer is placed in contact with the O-ring.
Page 230 V7 E5 Special-Stone Chassis • Rivet the nut at the groove on the pin- ion. CAUTION CAREFULLY CLEAN THE THREAD OF THE GEARBOX FROM LOCTITE RESIDUES BEFORE IN- SERTING THE PINION BEARING SUPPORT CASE AGAIN. • Using the protective jaws, block the gearbox in vice •...
Page 231 V7 E5 Special-Stone Chassis • Place the gearbox flange on the splash guard hub. • Place a new ring nut and using the spe- cific tool tighten it to the prescribed torque. Specific tooling 020999Y Crown counter- lock ring wrench •...
Page 232 V7 E5 Special-Stone Chassis • Using the specific tool, put it in a press and insert the inner track of the roller bearing. Specific tooling GU19927900 Punch for pressing the ring in- side the bearing • Insert the radial snap ring.
Page 233 V7 E5 Special-Stone Chassis • Insert a new sealing ring on the gear- box using the specific tool, paying at- tention to the direction of assembly. Specific tooling 021003Y Bevel gear oil seal punch • Using the specific tool, put it in a press and insert the outer track of the roller bearing until it stops.
Page 234 V7 E5 Special-Stone Chassis • Before proceeding with the assembly of the inner spacer, clean it thoroughly with an oil-soaked cloth. • Insert the inner spacer until it stops. • Reposition the crown axle thickness. NOTE THE THICKNESS HAS A UNIQUE POSITION IN THE BOX.
Page 235 V7 E5 Special-Stone Chassis • Insert the fixing screws of the flange and tighten it to the prescribed torque operating diagonally with the indicated sequence.. • After blowing the breather with com- pressed air, carefully remove any oil residues and check its correct func- tioning, put it in its seat again and tight- en it to the prescribed torque.
Page 236 V7 E5 Special-Stone Chassis • Insert and tighten the fastening screws (3) to the prescribed torque • Effettuare il riempimento olio seguendo quanto riportato nel capitolo "Manutenzione / Olio trasmissione / Sostituzione" See also Replacement Exhaust XHAUST SYSTEM Pos. Description...
Page 237 V7 E5 Special-Stone Chassis Pos. Description Type Quantity Torque Notes Fastening the RH/LH silencer heat 8 Nm (5.9 lbf ft) shield Fastening the silencer to the support 25 Nm (18.44 lbf ft) on the chassis Key: 1. Right exhaust manifold 2.
Page 238 V7 E5 Special-Stone Chassis 19.Right silencer 20.Left silencer 21.Right silencer support bracket 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 • Slide and remove the silencer from the...
Page 239 V7 E5 Special-Stone Chassis • Remove the three fixing screws of the silencer guard • Remove the silencer guard, sliding it toward the front of the vehicle • Loosen the clamp between the silencer and manifold CHAS - 239...
Page 240 V7 E5 Special-Stone Chassis • Remove the screw that fastens the si- lencer to the support bracket • Slide and remove the silencer from the collector Removing the exhaust manifold • First remove the fuel tank and the ex- haust tailpipes •...
Page 241 V7 E5 Special-Stone Chassis • Remove the nuts and the correspond- ing fixing washers of the exhaust mani- folds • Remove the exhaust manifolds at the same time Removing the lambda sensor • First remove the fuel tank • Disconnect from their support the con- nectors of the lambda probe wiring har- ness.
Page 242 V7 E5 Special-Stone Chassis • Unscrew and remove the lambda probe from the exhaust manifold Secondary air system Tightening torques 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)
Page 243 V7 E5 Special-Stone Chassis Key: 1. Air filter box 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...
Page 244 V7 E5 Special-Stone Chassis • Disconnect the Blow-by pipe from the reed valve cover • Undo the screws fastening the reed valve cover. • Remove the reed valve cover • Remove the reed valve. CHAS - 244...
Page 245 V7 E5 Special-Stone Chassis • Remove the flame trap. • A valve controlled by the engine ECU is installed under the tank, which al- lows the air from cylinders to flow via two flexible hoses. • This valve is connected directly to the filter box via a flexible hose.
Page 246 V7 E5 Special-Stone Chassis Evaporative emissions control system key: 1. Canister 2. SAE 30 R12A-3/16 pipe 3. Breather valve 4. SAE 30 R12A-1/4 pipe 5. SAE 30 R12A-1/4 pipe • The canister is installed with the intake inlet above the tank inlet •...
Page 247 V7 E5 Special-Stone Chassis • Check the correct passage of the pipes on the starter motor CHAS - 247...
Page 248 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 249 V7 E5 Special-Stone Braking system SYSTEM Pos. Description Type Quantity Torque Notes Control unit bracket fastening to the M6x16 10 Nm (7.38 lbf ft) frame Screw fastening brake lines fasten- 3 Nm (2.21 lbf ft) ing plates Clamp fastening screw 6 Nm (4.43 lbf ft)
Page 250 V7 E5 Special-Stone 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...
Page 251 V7 E5 Special-Stone 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 252 V7 E5 Special-Stone Braking system 20.Ring 21.Cable guide 22.Clip Operating diagram ABS functional diagram key BRAK SYS - 252...
Page 253 V7 E5 Special-Stone 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)
Page 254 V7 E5 Special-Stone Braking system At this stage the rider cannot increase the pressure on the callipers (8-9) and the system reduces the pressure on the callipers partially. The excess fluid temporarily fills the front reservoir (18-19) until the ABS pump (17) self-activates and delivers the fluid back to the brake pump (2-5).
Page 255 V7 E5 Special-Stone Braking system In this case, there are two possible results: • 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.
Page 256 V7 E5 Special-Stone Braking system • the ABS warning light turns off - if at least one malfunction is detected • the ABS warning light turns on permanently The ABS system is deactivated! The system operates perfectly just as any other braking system without ABS.
Page 257 V7 E5 Special-Stone Braking system NOTE: to carry out a check using the diagnostic tool on the wheel speed sensor, refer to the operations described in chapter ""ELECTRICAL SYSTEM/CHECKS AND CONTROLS/SPEED SENSOR" chapter. Use of diagnostics instrument for ABS system...
Page 258 V7 E5 Special-Stone 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, you can delete the errors from the memory of the controller and you can enable some systems controlled by the control unit.
Page 259 V7 E5 Special-Stone 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...
Page 260 V7 E5 Special-Stone 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. •...
Page 261 V7 E5 Special-Stone 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. •...
Page 262 V7 E5 Special-Stone Braking system Modulator Before removing the modulator, the braking system must be completely emptied. MODULATOR REMOVAL • Disconnect the connector of the lamb- da probe and move the wiring harness from the area in which the operations will be performed •...
Page 263 V7 E5 Special-Stone Braking system • Remove the front screws of the modu- lator support • Remove the side screw of the modula- tor support • Turn the modulator to the left to gain access to the lower fixing screw •...
Page 264 V7 E5 Special-Stone Braking system • Put a wipe under the modulator • Remove the brake pipe couplings from the modulator, making sure to retrieve all the copper seal washers • Remove the modulator's pipe guide • Remove the modulator from the vehi-...
Page 265 V7 E5 Special-Stone Braking system Rear brake calliper EAR BRAKE CALLIPER Pos. Description Type Quantity Torque Notes Rear brake calliper fixing screw 25 Nm (18.44 lbf ft) Screw fastening the calliper holder M16x1 35 Nm (25.81 lb ft) plate to the swingarm...
Page 266 V7 E5 Special-Stone Braking system 1. Rear brake calliper 2. Spacer 3. Brake calliper mounting plate 4. Screw fastening the plate to the swingarm 5. Screws fastening the calliper to the plate 6. Bleed + cap 7. Pins + spring kit 8.
Page 267 V7 E5 Special-Stone Braking system Front brake calliper RONT BRAKE CALLIPER Pos. Description Type Quantity Torque Notes Screws fastening front brake calliper 50 Nm (36.88 lb ft) Key: 1. Front left brake calliper BRAK SYS - 267...
Page 268 V7 E5 Special-Stone Braking system 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 •...
Page 269 V7 E5 Special-Stone Braking system (STONE) EAR WHEEL Pos. Description Type Quantity Torque Notes Rear brake disc fastening screws 25 Nm (18.44 lbf ft) Loctite 243 Rear wheel axle fastener pin + nut 100 Nm (73.77 lb ft) ABS sensor fixing screw 6 Nm (4.43 lbf ft)
Page 270 V7 E5 Special-Stone 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 271 V7 E5 Special-Stone Braking system • The following operations are to be car- ried out with brake disc fitted on the wheel. • Check the disc for wear by measuring the minimum thickness with a micro- meter in different points. If the mini-...
Page 272 V7 E5 Special-Stone Braking system 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 lbf ft) Loctite 243 ABS-sensor fixing stud bolt 6 Nm (4.43 lbf ft)
Page 273 V7 E5 Special-Stone Braking system • Remove the tone wheel (2) • Remove the brake disc (3) DURING REFITTING, APPLY LOCTITE 243 ON THE THREAD OF THE BRAKE DISC SCREWS (1). CAUTION DURING REFITTING, SCREW ALL THE SCREWS (1) MAN- UALLY AND TIGHTEN THEM OPERATING DIAGONALLY FOLLOWING THIS SEQUENCE: A-B-C-D-E-F.
Page 274 V7 E5 Special-Stone Braking system of the disc, is less than the minimum value, replace the disc. Disc thickness minimum value: 4 mm (0.16 in) • Using a dial gauge, check that the max- imum oscillation of the disc does not exceed the tolerance;...
Page 275 V7 E5 Special-Stone Braking system • Remove the brake pads Rear brake pads Removal • Remove the rear brake calliper • Remove the screws locking the brake pads • Remove the brake pads BRAK SYS - 275...
Page 276 V7 E5 Special-Stone Braking system 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" of the brake control and by poor braking efficiency.
Page 277 V7 E5 Special-Stone Braking system • Screw the bleeding valve and remove the pipe. • Top-up the reservoir until the correct brake fluid level is obtained. • Refit and block the front brake oil reservoir cap. • Refit the rubber protection cover.
Page 278 V7 E5 Special-Stone Braking system • Refit and lock the rear brake oil reservoir cap. • Refit the rubber protection cover. Front brake pump RONT BRAKE MASTER CYLINDER Pos. Description Type Quantity Torque Notes Front brake master cylinder U-bolt fixing 10 Nm (7.38 lbf ft)
Page 279 V7 E5 Special-Stone 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 PUMP Pos.
Page 280 V7 E5 Special-Stone Braking system Pos. Description Type Quantity Torque Notes Rear brake lever peg fastening 20 Nm (14.75 lbf ft) Loctite 243 Rear brake lever fixing pin 20 Nm (14.75 lbf ft) Fork fixing nut 10 Nm (7.38 lbf ft)
Page 281 V7 E5 Special-Stone Braking system • Remove the brake pump Brake system lines Removal • Drain the braking system • Remove the saddle • Remove the fuel tank • Remove the silencers CAUTION WHILE IT IS NOT MANDATORY TO REMOVE THE SILENCERS, WE RECOMMEND DOING SO IN ORDER TO AVOID CAUSING ANY SUPERFICIAL DAMAGE TO THEM.
Page 282 V7 E5 Special-Stone Braking system • Remove the brake pipe coupling from the front brake master cylinder • Retrieve the screw and the associated seal washers • Remove the rubber clamps fastening the switch cables to the brake pipe •...
Page 283 V7 E5 Special-Stone Braking system • Remove the brake pipe coupling from the front brake calliper • Retrieve the screw and the associated seal washers • Remove the cable ties fastening the ABS sensor cable to the brake pipe •...
Page 284 V7 E5 Special-Stone Braking system • Remove the clamp fastening the brake pipes to the chassis • Open the brae pipe fastener tab • Remove the brake pipe connector from the ABS modulator • Retrieve the screw and the associated seal washers •...
Page 285 V7 E5 Special-Stone Braking system • Remove the brake pipe coupling from the rear brake master cylinder • Retrieve the screw and the associated seal washers • Remove the vehicle's brake pipe REMOVING THE REAR BRAKE PIPE (BETWEEN THE BRAKE CALLIPERS AND THE ABS CON- TROL UNIT) •...
Page 286 V7 E5 Special-Stone Braking system • Remove the plate (1) from the brake pipe support bracket • Release the pipes from the bracket • Remove the brake pipe connector from the ABS modulator • Retrieve the screw and the associated seal washers •...
Page 287 V7 E5 Special-Stone Braking system • Remove the screw fixing the pipe feed- through to the swingarm • Remove the brake pipe coupling from the rear brake calliper • Retrieve the screw and the associated seal washers • Remove the vehicle's brake pipe...
Page 288 INDEX OF TOPICS BODYW ODYWORK...
Page 289 V7 E5 Special-Stone Bodywork EAR LIGHT ASSEMBLY Pos. Description Type Quantity Torque Notes Taillight to internal support fixing screws SWP 3 2 Nm (1.48 lb ft) Screws fastening the internal support to the SWP 3 2 Nm (1.48 lb ft)
Page 290 V7 E5 Special-Stone Bodywork EAR MUDGUARD Pos. Description Type Quantity Torque Notes Rear mudguard fixing screws 20 Nm (14.75 lbf ft) Front and centre fastening screw rear mud- 8 Nm (5.9 lb ft) guard Rear splash guard fastening screws 10 Nm (7.38 lbf ft)
Page 291 V7 E5 Special-Stone Bodywork 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 lbf ft) Pre-permeated Saddle release block fixing screws 10 Nm (7.38 lbf ft)
Page 292 V7 E5 Special-Stone Bodywork ILTER BOX Pos. Description Type Quantity Torque Notes Filter box fastening screws SWP M5 3 Nm (2.21 lbf ft) Air filter cover fastening screws SWP M5 3 Nm (2.21 lbf ft) Filter casing/frame fastening screw SWP M5 3 Nm (2.21 lbf ft)
Page 293 V7 E5 Special-Stone Bodywork Pos. Description Type Quantity Torque Notes Rear tank fastening screw 25 Nm (18.44 lbf ft) RONT MUDGUARD Pos. Description Type Quantity Torque Notes Screws fastening the stabiliser plate to the fork 15 Nm (11.06 lbf ft) Screw fastening the mudguard to the stabiliser 10 Nm (7.38 lbf ft)
Page 294 V7 E5 Special-Stone Bodywork EADLIGHT UNIT Pos. Description Type Quantity Torque Notes Headlamp fastening screws M8x45 15 Nm (11.06 lbf ft) Front turn indicators SHC fastening screws M6x25 10 Nm (7.38 lbf ft) SHC screws fastening the headlight support M6x25 10 Nm (7.38 lbf ft)
Page 295 V7 E5 Special-Stone Bodywork EADLIGHT UNIT 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 10 Nm (7.38 lbf ft) (HALOGEN VERSION) •...
Page 296 V7 E5 Special-Stone Bodywork 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 • Pull out the electrical connection to the bulb (2), and disconnect it from the bulb.
Page 297 V7 E5 Special-Stone Bodywork • Unscrew the two headlamps fixing screws • Support the headlamp and then re- move the screws (1) and the bushings • Release the safety (3) by sliding it in opposite direction to the headlamp •...
Page 298 V7 E5 Special-Stone Bodywork FRONT HEADLIGHT SUPPORT REMOVAL • Remove the front light assembly • Remove the front turn indicators • Unscrew and remove the screws (1) • Remove the upper U-bolt • Temporarily remove the handlebar from the lower U-bolts •...
Page 299 V7 E5 Special-Stone Bodywork • Remove the headlamp supports (5) from both sides of the vehicle Turn indicators REMOVING FRONT TURN INDICATORS The following procedure is described for one turn indicator, but it is valid for both turn indicators •...
Page 300 V7 E5 Special-Stone Bodywork • Disconnect the connector (4) • Undo and remove the screw (5) • Remove the front turn indicator (6) • Undo and remove the screw (5) BODYW - 300...
Page 301 V7 E5 Special-Stone Bodywork • Remove the front turn indicator (6) REAR TURN INDICATORS REMOVAL The following procedure is described for one turn indicator, but it is valid for both turn indicators • Remove the rear light cluster • Unscrew and remove the three fasten- ing screws (1) from the cover •...
Page 302 V7 E5 Special-Stone Bodywork • Remove the turn indicator (5) Disassembling the lock • Remove the LH side fairing • Remove the saddle opening cable (1) from its housing • Remove the fork spring (2) • Remove the cable support plate (3)
Page 303 V7 E5 Special-Stone Bodywork • Remove the ignition switch assembly Taillight assy. EAR LIGHT ASSEMBLY Pos. Description Type Quantity Torque Notes Taillight to internal support fixing screws SWP 3 2 Nm (1.48 lb ft) Screws fastening the internal support to the SWP 3 2 Nm (1.48 lb ft)
Page 304 V7 E5 Special-Stone Bodywork • Remove the rear mudguard from the vehicle • Remove the screws (1) that fasten the licence plate holder to the rear mud- guard and retrieve the centring bush- ings • Remove the lower reinforcement (2) from the mudguard •...
Page 305 V7 E5 Special-Stone Bodywork • Remove the licence plate light from the plate holder TAILLIGHT REMOVAL • Remove the plate holder from the rear mudguard • Remove the three nuts (3) that fasten the taillight to the mudguard • Loosen the screws (4) that fasten the...
Page 306 V7 E5 Special-Stone Bodywork • Remove the three fixing screws of the taillight half cases • Remove the upper half case of the tail- light • Disconnect the taillight connector (5) • Remove the fixing screws (6); • Remove the fixing screw (7) that was under the taillight connector •...
Page 307 V7 E5 Special-Stone Bodywork • Remove the fixing screws (8) and de- tach the taillight from its support Footrest (SPECIAL/STONE) REMOVAL OF THE RIGHT-HAND RIDER FOOTREST SUPPORT • Remove the gasket (1) • Unhook and remove the clip (2) •...
Page 308 V7 E5 Special-Stone Bodywork • Undo and remove the two fastening screws (4) • 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 •...
Page 309 V7 E5 Special-Stone Bodywork • Retrieve the O-ring (3) • Remove the rear brake lever (4) • Retrieve the O-ring (5) REMOVAL OF THE RIGHT-HAND RIDER FOOTREST • Remove the snap ring(1) BODYW - 309...
Page 310 V7 E5 Special-Stone Bodywork • Remove the pin (2) • Remove the right-hand rider footrest • Retrieve the spring (4) • Remove the clip (1) • Remove the gear shift lever tie-rod (2) from the ball joint • Undo and remove the two fastening...
Page 311 V7 E5 Special-Stone Bodywork • Remove the left-hand rider footrest support (4) 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) •...
Page 312 V7 E5 Special-Stone Bodywork REMOVAL OF THE LEFT-HAND RIDER FOOT- REST • Remove the snap ring(1) • Remove the pin (2) • Remove the left-hand rider footrest (3) • Retrieve the spring (4) REMOVAL OF THE PASSENGER FOOTRESTS SUPPORT •...
Page 313 V7 E5 Special-Stone Bodywork • Remove the right-hand passenger footrest support (4) • Repeat the entire operation to remove the left-hand passenger footrest sup- port REMOVAL OF THE PASSENGER FOOTREST • Remove the snap ring(1) • Remove the pin (2) •...
Page 314 V7 E5 Special-Stone Bodywork Side body panels 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 lbf ft) Side panel fastening screws 4 Nm (2.95 lb ft) •...
Page 315 V7 E5 Special-Stone Bodywork • Slide the side fairing forward • Disconnect the cable from the latch and then remove the side fairing from the vehicle NOTE The procedure described refers to the left side fairing but it is valid for both, except for the latch cable that doesn't exist on the right side.
Page 316 V7 E5 Special-Stone Bodywork • Remove the saddle, the side panels and the battery complete with the rub- ber support • Slide from the support present in the filter casing connector (1) and the ABS fuses (2) • Remove the four fastening screws (3) of the air filter cover •...
Page 317 V7 E5 Special-Stone Bodywork • Remove the two screws that fasten the air filter case to the chassis • 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 •...
Page 318 V7 E5 Special-Stone Bodywork • Remove the four screws securing the filter case support bracket and remove it by slightly raising the box itself • Pull the filter case from the right side of the motorcycle • Remove the collector from the filter case •...
Page 319 V7 E5 Special-Stone Bodywork • Remove the cover (8) and the blow-by filter (9) • 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 lbf ft) Front and centre fastening screw rear mud- 8 Nm (5.9 lb ft)
Page 320 V7 E5 Special-Stone Bodywork Pos. Description Type Quantity Torque Notes Rear splash guard fastening screws 10 Nm (7.38 lbf ft) • Remove the saddle • Unscrew and remove the two screws • Unscrew and remove the two fixing screws (2) from both sides of the vehi- •...
Page 321 V7 E5 Special-Stone 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...
Page 322 V7 E5 Special-Stone 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 lbf ft) Front and centre fastening screw rear mud- 8 Nm (5.9 lb ft)
Page 323 V7 E5 Special-Stone 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 - 323...
Page 324 V7 E5 Special-Stone 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 lbf ft) • Remove the saddle •...
Page 325 V7 E5 Special-Stone Bodywork • Remove the metal clamp • Remove the breather pipe from the tank coupling • Disconnect the fuel pipe coupling from the pump • Disconnect the fuel pump wiring har- ness connector • Remove the fuel tank from the vehicle...
Page 326 V7 E5 Special-Stone 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)
Page 327 V7 E5 Special-Stone Bodywork • Remove the four screws fixing the mudguard to the mudguard support • Remove the mudguard support from the mudguard BODYW - 327...
Page 328 ABS: 249, 257 Air filter: 58, 61, 62, 64 Battery: 118, 124 Brake: 265, 267, 268, 271, 274, 275, 278, 279, 281 Brake calliper: 265, 267 Brake disc: 268, 271 Brake pads: 274, 275 Brake pump: 278, 279 Bulbs: CAN line: 164 Clutch: 145 Coil: 141 Connectors: 152...
Page 329 Maintenance: 15, 51, 118 Mudguard: 319, 326 Oil filter: 57 Rear light: Rear wheel: 209 Recommended products: 53 Run/Stop switch: 150 SAS valve actuator: 149 Scheduled maintenance: 51 Secondary air system: 242 Shock absorbers: 204 Side stand: 147 Side stand sensor: 147 Spark plugs: Speed sensor: 125 Stand: 147...

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