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MOTO GUZZI V7 Classic Service Manual

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SERVICE STATION MANUAL
981078
V7 Classic

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Summary of Contents for MOTO GUZZI V7 Classic

  • Page 1 SERVICE STATION MANUAL 981078 V7 Classic...
  • Page 2 Not all versions 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 2008- 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 4 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 5 INDEX OF TOPICS CHAR HARACTERISTICS S-TOOLS PECIAL TOOLS MAIN AINTENANCE ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE P SUPP OWER SUPPLY SUSP USPENSIONS CHAS HASSIS BODYW ODYWORK PRE DE DELIVERY Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 6 INDEX OF TOPICS CHAR HARACTERISTICS Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...

  • Page 7: Safety Rules

    V7 Classic Characteristics Rules Safety rules Carbon monoxide If you need to keep the engine running in order to carry out any procedure, please ensure that you do so in an open or very well ventilated area. Never let the engine run in an enclosed area. If you do work in an enclosed area, make sure to use a smoke-extraction system.
  • Page 8 V7 Classic Characteristics 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. BRAKE AND CLUTCH FLUIDS ARE EXTREMELY HARMFUL FOR YOUR EYES.
  • Page 9 CAUTION BEARINGS MUST BE ABLE TO ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTH- ERWISE THEY NEED REPLACING. Only use ORIGINAL Moto Guzzi SPARE PARTS. Comply with lubricant and consumables usage guidelines. Lubricate parts (whenever possible) before reassembling them. When tightening nuts and screws, start from the ones with the largest section or from the internal ones, moving diagonally.

  • Page 10: Vehicle Identification

    That is to permit the adequate adjustment of the pad friction material to the brake discs. AFTER THE SPECIFIED MILEAGE, TAKE THE VEHICLE TO AN OFFICIAL Moto Guzzi DEALER FOR THE CHECKS INDICATED IN THE "AFTER-RUN" TABLE IN THE SCHEDULED MAINTE- NANCE SECTION TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHI- CLE.
  • Page 11 V7 Classic Characteristics This number consists of numbers and letters, as in the example shown below. ZGULW00008MXXXXXX KEY: ZGU: WMI (World manufacturer identifier) code; LW: model; 000: version variation; 0: digit free 8: variable year of manufacture (8 - for 2008) M: production plant (M= Mandello del Lario);...

  • Page 12: Electrical System

    V7 Classic Characteristics Specification Desc./Quantity Starter Electronic Engine revs at idle speed 1100 +/- 100 rpm Intake valve clearance 0.10 mm (0.0039 in) Outlet valve clearance 0.15 mm (0.0059 in) Clutch dry single-disc clutch with anti-vibration buffers Lubrication system Pressure system regulated by valves and a trochoidal pump Air filter dry cartridge air filter Cooling...

  • Page 13: Warning Lights

    V7 Classic Characteristics Specification Desc./Quantity Rear tail light /stop lights 12 V - 5 / 21 W Instrument panel lighting WARNING LIGHTS Specification Desc./Quantity Gear in neutral Turn indicators Fuel reserve High-beam light Engine oil pressure Injection check warning light Frame and suspensions CHASSIS Specification...

  • Page 14: Wheels And Tyres

    V7 Classic Characteristics 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 METZELER LASERTEC Front (size) 100 / 90 - 18 56H TL Front (inflation pressure) 2.2 bar (220 kPa) (31.90 PSI) Front (inflation pressure with passenger)

  • Page 15: Front Suspension

    V7 Classic Characteristics WINGARM Name Torque in Nm Swingarm on gearbox retainer - M20x1 (2) 0 Nm (0 lbf ft) - in support without preloading Lock nut on pin retainer - M20x1 (2) 50 Nm (36.88 lbf ft) - keep the pin firmly in place Swingarm to gearcase retainer - M8 (4) 25 Nm (18.44 lbf ft) - keep the pin firmly in place FRONT SUSPENSION...

  • Page 16: Fuel Tank

    V7 Classic Characteristics Name Torque in Nm Lever lock spacer retainer - M6x16 (1) 10 Nm (7.37 lbf ft) Rear brake rod lock nut - M6 (1) manual Brake pump retainer - M6x25 (2) 10 Nm (7.37 lbf ft) HANDLEBAR AND CONTROLS Name Torque in Nm Retainer for handlebar support U-bolts on steering plate -...

  • Page 17: Timing System

    V7 Classic Characteristics FINISHINGS Name Torque in Nm Ignition lock retainer - shear head screw - M8x15 (1) at the point of failure Ignition lock retainer - M8x16 (1) 25 Nm (18.44 lbf ft) Saddle opening lock retainer - M6x25 (2) 10 Nm (7.37 lbf ft) HEADS Name...
  • Page 18 V7 Classic Characteristics Name Torque in Nm Cover to gearbox fixing screws 10 Nm (7.37 lbf ft) Gearbox to clutch bell cover fixing screws 10 Nm (7.37 lbf ft) Index lever fixing nut 6 Nm (4.42 lbf ft) Recommended products chart ECOMMENDED PRODUCTS Product Description...
  • Page 19 INDEX OF TOPICS S-TOOLS PECIAL TOOLS Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...

  • Page 20: Special Tools

    V7 Classic Special tools SPECIAL TOOLS Stores code Description 19.92.61.00 Punch for sealing ring of bevel gear pair pinion 19.92.88.00 Bevel gear pair alignment pre-fitting tool 19.92.60.00 Punch for gearcase sealing ring 19.90.70.00 Extractor for internal ring on drilled bolt 19.92.75.00 Extractor for external ring of gearcase bearing...
  • Page 21 V7 Classic Special tools Stores code Description 19.92.64.00 Punch for external ring of tapered bearing on bevel gear pair 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 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten S-TOOLS - 21...
  • Page 22 INDEX OF TOPICS MAIN AINTENANCE Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...

  • Page 23: Maintenance Chart

    V7 Classic Maintenance Maintenance chart NOTE CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SHOWN IF THE VEHICLE IS USED IN WET OR DUSTY AREAS, OFF ROAD OR FOR SPORTING APPLICATIONS. I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE * Check and clean, adjust or replace if necessary before every ride.
  • Page 24 V7 Classic Maintenance Check • Keep the vehicle upright with both wheels on the ground. • Unscrew and remove the cap/dipstick (1). • The level is correct if the oil is close to the hole of the cap/dipstick (1). • If the oil is lower than specified, top-up until it reaches the cap/dipstick hole (1).

  • Page 25: Engine Oil

    V7 Classic Maintenance 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 AND REACH THE OPERATING TEMPERATURE OF ENGINE OIL. OIL IS BEST CHECKED AFTER RUNNING FOR ABOUT 15 KM (10 miles).

  • Page 26: Engine Oil Filter

    V7 Classic Maintenance Replacement Place a container with + 2000 cm³ (122 cu.in) capacity under the drainage plugs (1). Unscrew and remove the drainage plugs (1). Unscrew and remove the filler cap (2). Drain the oil into the container; allow several minutes for oil to drain out com- pletely.

  • Page 27: Air Filter

    V7 Classic Maintenance Air filter Remove the fuel tank. Disconnect the two horn connectors. Undo and remove the horn fixing screw. Working on both sides, undo and re- move the two air filter casing cover screws. Remove the oil breather pipe. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten MAIN - 27...

  • Page 28: Braking System

    V7 Classic Maintenance Slide off the air filter casing cover from the right side of the vehicle. Remove the air filter. Braking system Level check Brake fluid check Place the vehicle on the service stand. For the front brake, turn the handlebar fully to the right. For the rear brake, keep the vehicle upright so that the fluid in the reservoir is at the same level with the plug.
  • Page 29 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. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 30 V7 Classic Maintenance Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten MAIN - 30...
  • Page 31 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 32 V7 Classic Electrical system Components arrangement Key: 1. Instrument panel 2. Coil 3. Fuel pump Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten ELE SYS - 32...
  • Page 33 V7 Classic Electrical system 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 15.Auxiliary fuses 16.Starter motor 17.Lambda Probe 18.Voltage regulator 19.Oil pressure sensor...
  • Page 34 V7 Classic Electrical system Front side CAUTION ONCE THE ELECTRICAL SYSTEM IS REFITTED, THE CONNECTORS RECONNECTED AND CLAMPS AND RETAINERS RESTORED, CARRY OUT THE CHECKS INDICATED UNDER "SPE- CIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES" IN THE "ELEC- TRICAL SYSTEM INSTALLATION"...
  • Page 35 V7 Classic Electrical system TABLE C Arrange the throttle control transmissions. 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: the first clamp fixed to the chassis in the opening;...
  • Page 36 V7 Classic Electrical system After connecting the quick connectors to the pump, check that it has fitted correctly by pulling the connector in the opposite direction. Locking torques (N*m) Pump support to tank retainer - M5x16 (6) 6 Nm (4.42 lbf ft) TABLE B Clamp the tank drainage pipes to the ground with the oil scavenge pipes so that they do not touch...
  • Page 37 V7 Classic Electrical system TABLE E Clamp the main cable harness onto the central part of the left hand spar with two clamps (3) and on the pipe joining tube the tank attachment (right side) (4) with one clamp. 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.
  • Page 38 V7 Classic Electrical system General wiring diagram Key: 1. Multiple connectors 2. Revolution sensor 3. Oil pressure sensor 4. Left coil Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten ELE SYS - 38...
  • Page 39 V7 Classic 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 19.FLYWHEEL 20.Battery...
  • Page 40 V7 Classic 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 B blue Bi white G yellow...
  • Page 41 V7 Classic 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". Wait for the Key OFF. The next time the vehicle is started, the value will be reset and the word "MAInt"...
  • Page 42 V7 Classic Electrical system Specification Desc./Quantity Front daylight running light 12V - 5W Turn indicator light 12 V - 10 W (orange RY 10 W bulb) License plate light 12V - 5 W Rear tail light /stop lights 12 V - 5 / 21 W Instrument panel lighting Fuses FUSE DISTRIBUTION...

  • Page 43: Control Unit

    V7 Classic 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 44 V7 Classic 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) DIAGNOSIS Speed viewing problems on the instrument panel CARRY OUT THE CASCADE OPERATIONS UNTIL THE FAILURE IS FOUND...
  • Page 45 V7 Classic Electrical system Pin-out: 1. Engine revolution sensor positive signal 2. Engine revolution sensor negative signal 3. Revolution sensor anti-jamming cable AXONE: PARAMETERS Target engine revs Example value:1100 +/- 100 rpm Parameter valid at idle, setting depends especially on engine temperature: the ECU unit will try to keep the engine running at this revs, acting on the ignition advance.
  • Page 46 V7 Classic Electrical system sensor: on the right cylinder throttle body connector: on the potentiometer Electrical characteristics: PINS A-C: throttle closed approximately 1.7 kOhm; throttle open approximately 1.1 kOhm. PINS A-B: approximately 1 kOhm. Pin-out: A: ground connection B: supply voltage +5V C: potentiometer signal (from 0.5 V with closed throttle to 4 V with open throttle) AXONE: PARAMETERS...
  • Page 47 V7 Classic Electrical system AXONE: ADJUSTABLE PARAMETERS Self-adjustable parameters reset: Lambda probe: operation to be carried out after the throttle body is cleaned, or in the case a new engine, a new lambda probe or a new injector is fitted, or the correct operation of the injection system or the valves is restored.
  • Page 48 V7 Classic Electrical system Orange (cable harness side): 0-5 V sig- AXONE: PARAMETERS Engine temperature In case of failure, the value read on Axone (20°C - 68°F) is set by the control unit, so it is not a real value. AXONE: ELECTRICAL ERRORS engine temperature sensor - open circuit, shorted to positive / shorted to negative.
  • Page 49 V7 Classic 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 50 V7 Classic Electrical system nector and the PIN related to the pink/black cable (cable harness side) of the sensor: restore cable harness if there is not continuity; if it is OK, reconnect the control unit connector and, with key set to ON, check continuity between the PIN related to the grey cable (cable harness side) of the sensor and the vehicle ground connection: if there is not continuity, restore cable harness;...
  • Page 51 V7 Classic Electrical system 1. Sensor signal + (black wire) 2. Sensor signal - (grey wire) 3. Heater ground connection (white) 4. Heater power supply (white) AXONE: PARAMETERS Lambda probe Example value: 0 - 1000 mV If there is a short circuit at + 5 V or higher, the read value is equal to approximately 1250 mV (the corresponding error will be displayed on the Axone).
  • Page 52 V7 Classic Electrical system 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; if OK, check if there is battery voltage on PIN 3 (red/brown cable) on the cable harness side for 2 seconds upon "key ON"...
  • Page 53 V7 Classic Electrical system If shorted to positive: excessive voltage has been detected at PIN 13 of the control unit connector. If shorted to negative: no voltage has been detected. If the circuit is open: an interruption has been detected Troubleshooting If shorted to positive: disconnect the injector connector, set the key to ON and check if there is voltage on the grey/red cable: if there is voltage, restore the cable harness;...
  • Page 54 V7 Classic Electrical system with the ground connection, restore the cable harness; if there is not continuity, replace the injector. The circuit is open: check the component correct electrical characteristic: if it is not the cor- rect one, replace the component; if it is correct, check the connector on the component and the Marelli control unit connector: If not OK, restore;...
  • Page 55 V7 Classic Electrical system of the wiring is necessary for correct activation: no error indications are displayed in case of lack of activation. AXONE: ELECTRICAL ERRORS Left coil - shorted to positive / open circuit, shorted to negative. Error cause If shorted to positive: excessive voltage has been detected at PIN 20 of the control unit connector.
  • Page 56 V7 Classic Electrical system two cable terminals. If there is no continuity, restore the cable harness; if there is cable continuity, with key set to ON, check the cable earth insulation (from coil connector or control unit connector). If not OK, restore the cable harness. Engine oil pressure sensor Function:it indicates the instrument panel if there is enough oil pressure 0.35 +/- 0.2 bar (5.1 +/- 2.9...
  • Page 57 V7 Classic Electrical system Neutral sensor Function it tell the gear position to the instrument panel: if it is in neutral or in gear. Operation / Operating principle for neutral gear, the circuit is closed to ground connection: the instrument panel turns on the neutral warning light.
  • Page 58 V7 Classic Electrical system sensor: under clutch lever connector: under the fuel tank Electrical characteristics: Clutch pulled: closed circuit (continuity) Clutch released: open circuit (infinite resistance) Pin-out: 1. Ground connection 2. Voltage 12V DIAGNOSIS Although the clutch lever is operated, the vehicle does not start. Check that if the gear is engaged, the stand is retracted;...

  • Page 59: Bank Angle Sensor

    V7 Classic Electrical system 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 stand switch always open): check continuity of the green/brown cable between PIN 2 of diode 40 (wiring diagram) and the corresponding PIN of the sensor connector on the cable harness side.
  • Page 60 V7 Classic Electrical system 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 61 V7 Classic Electrical system "---" 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 sensor circuit is open or shorted to positive/negative Troubleshooting Check the sensor connector and the instrument panel connector (PIN 12): if it is not OK, restore;...
  • Page 62 V7 Classic Electrical system voltage 0 V with engine kill in STOP; 12 V with engine kill in RUN. Orange/red cable (cable harness side): always voltage 12 V (with key on) DIAGNOSIS Engine does not start: disconnect the connector and with switch set to RUN, check if there is continuity between the two grey/light blue and red/green cables (sensor side): if there is not continuity, replace the sensor;...
  • Page 63 V7 Classic Electrical system 10.Diagnosis line (L) - Communication line 11.Throttle position signal - Analogue input 12.Engine revolution sensor - Frequency input 13.Right injector control - Power output 14.Right coil control - Power output 15.Injection telltale light control - Digital output 16.Fall sensor signal - Digital input 17.Control unit supply - Power input 18.Intake air temperature sensor signal - Ana-...
  • Page 64 V7 Classic Electrical system 17.Speed input 18.Engine revs input 19.n.c. 20.Reserve input 21.Key 22.Ground connection 23.Battery 24.Front right arrow output 25.Rear right arrow output 26.Battery Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten ELE SYS - 64...
  • Page 65 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 66 V7 Classic 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 67 V7 Classic Engine from vehicle Remove the revolution sensor but keep it connected to the cable harness. Slide the pin, with the split pin, fixing the linkage to the clutch to the engine block and then release the control ca- ble.
  • Page 68 V7 Classic 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. Loosen the clamps on the intake mani- folds.
  • Page 69 V7 Classic Engine from vehicle Remove the connection of the engine temperature sensor. Disconnect the starter motor and the lambda probe. Open the clamp and disconnect the oil breather pipe of the air filter casing. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten ENG VE - 69...
  • Page 70 V7 Classic Engine from vehicle Disconnect the neutral indicator. Disconnect the connector of the side stand safety switch and slide off the cable harness from the chassis. 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 71 V7 Classic Engine from vehicle Undo the screw fixing the ground eye- let on the engine block. Support the vehicle chassis by means of a hoister. Undo the four Allen head screws fixing the front arms of the chassis to the en- gine cradle.
  • Page 72 V7 Classic Engine from vehicle During this removal operation, discon- nect the connection of the oil pressure transmitter. Installing the engine to the vehicle Secure the scooter chassis by fasten- ing it with a hoister and lift the engine to place it in its position. During this operation, connect again the oil pressure transmitter connection and check that the throttle body...
  • Page 73 V7 Classic 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 74 V7 Classic 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. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten ENG VE - 74...
  • Page 75 V7 Classic 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. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten ENG VE - 75...
  • Page 76 V7 Classic 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. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten ENG VE - 76...
  • Page 77 V7 Classic 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. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten ENG VE - 77...
  • Page 78 INDEX OF TOPICS P SUPP OWER SUPPLY Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...

  • Page 79: Circuit Diagram

    V7 Classic Power supply Circuit diagram Key: 1. Fuel tank 2. Throttle body 3. Fuel filter 4. Fuel delivery pipe 5. Fuel pump unit Injection Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten P SUPP - 79...
  • Page 80 V7 Classic 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 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten P SUPP - 80...
  • Page 81 V7 Classic Power supply 13.Fall sensor 14.Side stand Cylinders synchronisation With engine off, connect the Axone 2000 tool to the diagnosis connector and to the vehicle battery. Turn on the scanner. Screw the joints connecting the vacu- ometer pipes on the inlet pipe holes. Connect the vacuometer pipes to the relative joints.
  • Page 82 V7 Classic Power supply Start the engine. Take the engine to the prescribed tem- perature: 50 °C (122 °F). Completely close the two by-pass screws on the throttle bodies. Take the engine to an out-of-idle speed: 2000 - 3000 rpm. Check cylinder compensation on the vacuometer.
  • Page 83 V7 Classic Power supply Co rate adjustment It is not possible to adjust CO (time of injectors opening) but just resetting the self-adjustable parameters in case the throttle body is replaced because it is worn. Iso screen page This display shows general data regarding the control unit, for example software type, mapping, control unit programming date ISO DISPLAY...
  • Page 84 V7 Classic Power supply Specification Desc./Quantity Lambda integrator When the control unit uses the lambda probe signal (see the 'Lambda' parameter on the 'Device status' display) this value should be close to 0% Partial load self-adjustment Supplementary correction factor for the injection time, in out- of-idle condition.
  • Page 85 V7 Classic Power supply Devices activation screen page DEVICES ACTIVATION This display is used to delete errors in the control unit memory and to activate some systems con- trolled by the control unit. DEVICES ACTIVATION Specification Desc./Quantity Error clearing By pressing the 'enter' button, the stored errors (MEM) become part of the historical data (STO).
  • Page 86 V7 Classic Power supply Specification Desc./Quantity Fuel pump relay Possible short circuit in the earth lead, battery or open circuit: the engine does not start. Self-adjustable parameters RAM memory Possible internal control unit error. Also check the control unit supply and earth connections ROM memory Possible internal control unit error.
  • Page 87 INDEX OF TOPICS SUSP USPENSIONS Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...

  • Page 88: Removing The Front Wheel

    V7 Classic Suspensions Front Removing the front wheel Place the vehicle on a stable support so that the front wheel does not touch the ground. Remove the brake calliper without dis- connecting the oil pipes Remove the front wheel. Front fork Diagram Key: 1.
  • Page 89 V7 Classic Suspensions 3. Screw 4. Complete left sleeve 5. Upper bushing 6. Washer 7. Sealing ring 8. Snap ring 9. Dust guard 10.Stem 11.Lower bushing 12.Buffer 13.Counter spring 14.Complete pumping member 15.Spring 16.Pipe 17.Complete cap 18.Screw 19.Base with headstock 20.Ring nut 21.Fork upper plate 22.Washer...

  • Page 90: Removing The Fork Legs

    V7 Classic Suspensions Removing the fork legs The vehicle is equipped with a non adjustable fork. The operations described below are valid for both stems. CAUTION DURING THE OPERATIONS DESCRIBED BELOW, THE STEMS AND THEIR INTERNAL COMPO- NENTS SHOULD BE TIGHTENED ON A VICE. MAKE SURE NOT TO DAMAGE THEM BY OVER- TIGHTENING;...
  • Page 91 V7 Classic Suspensions Undo the lower sealing screw. Slide off the stem downwards by turning it slightly first in one direction then to the opposite direction. Draining oil To drain out the oil follow these steps. Remove the fork stem. Tighten the removed stem in a vice fit- ted with aluminium jaw caps in order to avoid damaging them.
  • Page 92 V7 Classic Suspensions Be careful not to damage the O-Ring during extraction. Press the bearing tube inside the wheel holder fork leg. Remove the preload tube and the spring. Drain out all the oil inside the stem. NOTE FOR EASY DRAINAGE OF THE OIL INSIDE THE PUMPING MEMBER ROD, PRESS THE STEM IN THE WHEEL HOLD- ER SLEEVE TO PUMP OIL OUT.
  • Page 93 V7 Classic Suspensions Remove the dust scraper using a screwdriver as a lever. CAUTION BE CAREFUL NOT TO DAMAGE THE FORK LEG RIM AND THE DUST SCRAPER. Slide the dust scraper off and upwards. Remove the locking ring inside the fork leg using a thin screwdriver.
  • Page 94 V7 Classic Suspensions Checking the components Check every component removed from the fork leg, specially: the sealing ring and the dust guard as they are ele- ments that guarantee sealing; replace them if some of them are damaged. Check the bushing on the bearing tube; remove it and replace it if damaged or worn.
  • Page 95 V7 Classic Suspensions Insert the lower sliding bushing in its seat on the bearing tube. Reassemble the bearing tube in the wheel holder fork leg. 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.
  • Page 96 V7 Classic Suspensions 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. Fit the locking ring. Fit the dust scraper. Pour oil into the bearing tube so that it also fills the internal grooves of the pumping member rod.
  • Page 97 V7 Classic Suspensions Filling oil Place the sleeve upright in a vice fitted with protection jaws. Compress the sleeve in the stem. Pour part of the fork oil into the sleeve. Wait some minutes until the oil fills all the ducts. Pour the remaining oil.

  • Page 98: Installing The Fork Legs

    V7 Classic 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. Tighten the screws to the prescribed torque.
  • Page 99 V7 Classic Suspensions Steering bearing 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. Remove the instrument panel. Working from both sides, undo and re- move the screw locking the upper plate to the front fork.

  • Page 100: Shock Absorbers

    V7 Classic 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. Fit the instrument panel. Rear Shock absorbers Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 101 V7 Classic Suspensions Removing Undo and remove the upper screw. Undo and remove the lower screw. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten SUSP - 101...
  • Page 102 INDEX OF TOPICS CHAS HASSIS Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 103 V7 Classic Chassis Swinging arm Removing Remove the left silencer. 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. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten CHAS - 103...
  • Page 104 V7 Classic Chassis Unscrew and remove the nut and col- lect the washer. Loosen the wheel pin locking screw. Remove the wheel pin and collect the spacer. Remove the rear wheel. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten CHAS - 104...
  • Page 105 V7 Classic Chassis Unscrew the seal clamp. Lift the bellows. 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 106 V7 Classic Chassis Check that the rubber bellows are not cut or pierced; otherwise, replace it. Check that the swingarm pin threads and the swingarm fixing nuts are not damaged, de- formed or flattened; otherwise, replace them. Check that the sleeve grooves are not damaged, deformed or deteriorated; otherwise, re- place the sleeve.
  • Page 107 V7 Classic Chassis Screw the clamp. Fit the rear wheel. Bevel gears Removing Undo the four nuts and collect the washers. Slide off the gearcase together with the swingarm. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten CHAS - 107...
  • Page 108 V7 Classic Chassis Slide off the sleeve from the pinion. Slide off the spring. Slide off the sealing ring. Slide off the base. Slide off the gear. Checking Pinion unit Remove the housing of the swingarm . Slide the complete case of the gear- case.
  • Page 109 V7 Classic Chassis Insert the grooved shank of the pinion on the tool and unscrew the nut. Slide off the spacer. Slide off the pinion. Slide off the shim adjustment washer. Slide off the O-ring. Slide off the oil seal. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten CHAS - 109...
  • Page 110 V7 Classic Chassis Slide of the tapered bearing from the case. Slide off the O-ring. Slide off the spacer. Slide off the two shim washers. Slide off the tapered bearing from the case. Checking Check that the pinion toothing is not damaged, worn or deformed; otherwise, replace the pair.
  • Page 111 V7 Classic 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 112 V7 Classic Chassis Fit both shim washers on the pinion. Fit the spacer on the pinion. Fit the O-ring. Fit the complete pinion on the case us- ing the suitable punch (19926100). Fit the oil seal. Fit the O-ring. Fit the spacer. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten CHAS - 112...
  • Page 113 V7 Classic Chassis Insert the grooved shank of the pinion on the tool (19907100) and tighten the nut. Casing unit removal 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.
  • Page 114 V7 Classic Chassis From the cover, slide off: The needle bearing. Remove the internal ring of the needle bearing using a suitable punch (19907000). Remove the washer. Remove the washer. Undo the screws and collect the corre- sponding safety plates. Remove the conical crown.
  • Page 115 V7 Classic Chassis Remove the sealing ring. 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- Checking Check that the drilled bolt tongues, where the anti-vibration rubbers operate, are not spoiled;...
  • Page 116 V7 Classic Chassis on the housing; the groove for the circlip on the drilled bolt are not worn, deformed or spoiled; otherwise, replace them. Check that the sealing ring on the housing is not shattered or is still flexible; otherwise, replace it.
  • Page 117 V7 Classic Chassis Apply suitable colours available in the market on the pinion teeth. 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"...
  • Page 118 V7 Classic Chassis If the contact is like this, the crown is too near the pinion rotation axis: de- tach the crown by increasing spacer thickness. If the contact is like this, the pinion is too near the rotation axis of the crown: detach the pinion by reducing spacer thickness If the contact is like this, the pinion is...
  • Page 119 V7 Classic Chassis Fit the washer on the gearcase. Fit the sealing ring on the housing us- ing the suitable punch (19926000). Fit the external ring of the needle bear- ing on the housing using the suitable punch (19926500). Fit the bearing on the cover using the suitable punch.
  • Page 120 V7 Classic 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. Fit the crown. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten CHAS - 120...
  • Page 121 V7 Classic Chassis Fit the plates and tighten the screws. Insert the washer. Insert the washer. Fit the O-ring. Insert the gaskets and the shimming ring on the cover. Tighten the screws with plates and washers. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten CHAS - 121...
  • Page 122 V7 Classic Chassis Fit the braking disc on the drilled bolt by locking the screws with the washers using a torque wrench. When refitting the bevel pinion case on the transmission, bear in mind that the oil passage grooves with holes should be fitted vertically (observing the grooves, one should be facing up- wards and the other facing the ground).
  • Page 123 V7 Classic 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. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten CHAS - 123...
  • Page 124 V7 Classic Chassis Exhaust Key: 1. Right exhaust pipe 2. Left exhaust pipe 3. Expansion chamber 4. Left silencer clamp 5. Gasket 6. Spacer 7. Ring nut 8. Washer 9. Nut 10.Left silencer 11.Right silencer 12.Clamp 13.Right plate 14.Left plate 15.Right silencer clamp 16.Muffler rubber ring 17.TCEI screw...
  • Page 125 V7 Classic Chassis 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 shut off. Before handling these components, make sure that you are wearing insulating gloves or wait until the engine and the exhaust system have cooled down.
  • Page 126 V7 Classic Chassis Unscrew and remove the lambda probe. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten CHAS - 126...
  • Page 127 INDEX OF TOPICS BODYW ODYWORK Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 128 V7 Classic Bodywork Fuel tank Unscrew and remove the rear screw. Disconnect the connector. Disconnect the fuel pipe. Remove the fuel bleeding pipe. Remove the fuel tank by sliding it off and back. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten BODYW - 128...
  • Page 129 INDEX OF TOPICS PRE DE DELIVERY Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 130 V7 Classic Pre-delivery Carry out the listed checks before delivering the vehicle. WARNING BE EXTREMELY CAUTIOUS WHEN HANDLING FUEL. Aesthetic inspection - Paintwork - Fitting of Plastic Parts - Scratches - Dirt Tightening torques inspection - Safety locks: front and rear suspension unit front and rear brake calliper retainer unit front and rear wheel unit engine - chassis retainers...

  • Page 131: Road Test

    V7 Classic 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. CAUTION TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.
  • Page 132 V7 Classic 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 - Starter operation (if present) - Minimum holding (turning the handlebar) - Uniform turning of the steering...
  • Page 133 Air filter: 27 Battery: 43 Bulbs: Clutch: 57 Clutch lever: 57 Display: 85 Engine oil: 25, 56 Fork: 88, 90, 92, 94, 98 Fuel: 128 Fuses: 42 Identification: 10 Instrument panel: 60 Maintenance: 8, 23 Oil filter: 26 Recommended products: 18 Shock absorbers: 100 Spark plugs: Stand: 58...
  • Page 134 Warning lights: Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...

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