MOTO GUZZI V7 CLASSIC Service Manual Download Page 121

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Fit the plates and tighten the screws.

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Insert the washer.

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Insert the washer.

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Fit the O-ring.

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Insert the gaskets and the shimming

ring on the cover.

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Tighten the screws with plates and

washers.

V7 Classic

Chassis

CHAS - 121

Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

Summary of Contents for V7 CLASSIC

Page 1: ...SERVICE STATION MANUAL 981078 V7 Classic ...

Page 2: ...Guzzi Original Spare Parts are subject to systematic quality control procedures so that their reliability and performance over time is guaranteed The descriptions and illustrations given in this publication are not binding while the basic features as described and illustrated in this manual remain unchanged Moto Guzzi reserves the right at any time and without being required to update this publica...

Page 3: ...municated to all Moto Guzzi Sales Outlets and its International Subsidiaries These changes will be introduced in the subsequent editions of the manual In case of need or further queries on repair and check procedures consult Moto Guzzi CUSTOMER DEPARTMENT which will be prepared to provide any information on the subject and any further communications on updates and technical changes related to the ...

Page 4: ...Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 5: ... TOOLS S TOOLS MAINTENANCE MAIN ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE POWER SUPPLY P SUPP SUSPENSIONS SUSP CHASSIS CHAS BODYWORK BODYW PRE DELIVERY PRE DE Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 6: ...INDEX OF TOPICS CHARACTERISTICS CHAR Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 7: ...HEM TO IGNITE OR EXPLODE DO NOT DISPOSE OF FUEL INTO THE ENVIRONMENT KEEP OUT OF THE REACH OF CHILDREN Hot components 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 ha...

Page 8: ...Y MILK OF MAGNESIA OR VEGETA BLE OIL AND SEEK MEDICAL ADVICE IMMEDIATELY THE BATTERY RELEASES EXPLOSIVE GASES KEEP IT AWAY FROM FLAMES SPARKS CIGARETTES OR ANY OTHER HEAT SOURCE ENSURE ADEQUATE VENTILATION WHEN SERVICING OR RECHARGING THE BAT TERY KEEP OUT OF THE REACH OF CHILDREN BATTERY LIQUID IS CORROSIVE DO NOT POUR OR SPILL IT PARTICULARLY ON PLASTIC COMPONENTS ENSURE THAT THE ELECTROLYTIC AC...

Page 9: ...r in an area with low traffic density Clean all junction surfaces oil guard rims and washers before refitting them Smear a light layer of lithium based grease on the oil guard rims Reassemble the oil guard and the bear ings with the brand or lot number facing outward visible side ELECTRIC CONNECTORS Electric connectors must be disconnected as described below as non compliance with the procedure so...

Page 10: ...AL AND WILL DISAPPEAR AS SOON AS THE CLUTCH PLATES GET ADAPTED IT IS IMPORTANT TO STRAIN ENGINE COMPONENTS DURING RUN IN HOWEVER MAKE SURE NOT TO OVERDO THIS CAUTION ONLY AFTER THE SERVICE AT THE END OF THE RUN IN PERIOD CAN THE BEST PERFORM ANCE OF YOUR VEHICLE BE OBTAINED Follow the guidelines detailed below Do not twist the throttle grip abruptly and completely when the engine is working at a l...

Page 11: ...he left side close to the engine oil level check cap Dimensions and mass WEIGHT AND DIMENSIONS Specification Desc Quantity Max length 2185 mm 86 in Max width 800 mm 31 5 in Max height 1115 mm 43 9 in Saddle height 805 mm 31 69 in Wheelbase 1435 mm 56 5 in Minimum ground clearance 182 mm 7 16 in Kerb weight 198 kg 436 lb Engine ENGINE Specification Desc Quantity Type 90 transversal V twin four stro...

Page 12: ...825 Capacities CAPACITY Specification Desc Quantity Fuel reserve included 15 l 3 30 UKgal 3 96 USgal Fuel reserve 2 5 l 0 55 UKgal 0 66 USgal Engine oil oil change and oil filter replacement 1780 cm 108 62 cu in Gearbox oil 1 l 0 26 USgal Transmission oil 170 cm 10 37 cu in Seats 2 Vehicle maximum load 203 kg 447 lb rider passenger luggage Electrical system ELECTRICAL SYSTEM Specification Desc Qua...

Page 13: ...8 mm 5 43 in SUSPENSIONS Specification Desc Quantity Front hydraulic telescopic fork Ø 40 mm 1 57 in Travel 130 mm 5 12 in Rear swinging arm in die cast light alloy 2 shock absorbers with ad justable spring preloading Wheel travel 100 mm 3 93 in SIZES A AND B Specification Desc Quantity Size A 692 mm 27 24 in Size B 186 mm 7 32 in Brakes BRAKES Specification Desc Quantity Front stainless steel flo...

Page 14: ...lbf ft Engine gearbox to chassis retainer M10 1 1 50 Nm 36 88 lbf ft Gearbox to chassis retainer M12x55 2 50 Nm 36 88 lbf ft Stand to cradles transverse retainer M10x260 1 50 Nm 36 88 lbf ft Stand to cradles transverse retainer M8 1 1 25 Nm 18 44 lbf ft Battery housing plate retainer M8x16 4 25 Nm 18 44 lbf ft Left and right rider footrest support to chassis retainer M8x20 2 2 25 Nm 18 44 lbf ft L...

Page 15: ...or retainer 2 2 Nm 1 47 lbf ft EXHAUST Name Torque in Nm Exhaust pipe to engine retainer M6 2 2 10 Nm 7 37 lbf ft Exhaust pipe to compensator retainer clamp M6 2 10 Nm 7 38 lbf ft Exhaust pipe to silencer retainer clamp M6 1 1 10 Nm 7 37 lbf ft Lambda probe retainer M18x1 5 1 38 Nm 28 03 lbf ft Mufflers to support retainer M8x25 4 25 Nm 18 44 lbf ft Loctite 601 Right and left heat guard bulkhead r...

Page 16: ...ear turn indicator retainer screw nut M6 2 2 5 Nm 3 69 lbf ft Rear light support to mudguard retainer M5x14 3 4 Nm 2 95 lbf ft FUEL PUMP FLANGE Name Torque in Nm Pump support to tank retainer M5x16 6 6 Nm 4 42 lbf ft FUEL TANK Name Torque in Nm Cap flange to fuel tank retainer M5x12 5 4 Nm 2 95 lbf ft Tank rear retainer M8x45 1 25 Nm 18 44 lbf ft CHASSIS FAIRINGS FRONT Name Torque in Nm Stabiliser...

Page 17: ... lbf ft Flywheel to crankshaft fixing screw 40 Nm 29 50 lbf ft Crown gear fixing screw 10 Nm 7 37 lbf ft TIMING SYSTEM Name Torque in Nm Camshaft to crankcase retaining joint 30 Nm 22 12 lbf ft Gear on camshaft fixing screws 25 Nm 18 43 lbf ft Tone wheel fixing screw 25 Nm 18 43 lbf ft ELECTRIC STARTING SYSTEM Name Torque in Nm Starter motor fixing screws 25 Nm 18 43 lbf ft FUEL SUPPLY CONTROL UNI...

Page 18: ...oil AGIP GEAR MG S SAE 85W 90 Gearbox oil AGIP FORK 7 5W Fork oil SAE 5W SAE 20W AGIP GREASE SM2 Lithium grease with molybdenum for bearings and other points needing lubri cation NLGI 2 Neutral grease or petroleum jelly Battery poles AGIP BRAKE 4 BRAKE 5 1 Brake fluid As an alternative for recommended fluids use top branded fluids that meet or ex ceed the requirements of SAE J1703 NHTSA 116 DOT 4 ...

Page 19: ...INDEX OF TOPICS SPECIAL TOOLS S TOOLS Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 20: ...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 19 92 62 00 Punch for bearing on bevel gear pair pin ion Special tools V7 Classic S TOOLS 20 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 21: ... on bevel gear pair pinion holding body 19 92 65 00 Punch for external ring of gearcase bear ing 19 92 76 00 Extractor for swinging arm holder bearing on gearbox cover V7 Classic Special tools S TOOLS 21 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 22: ...INDEX OF TOPICS MAINTENANCE MAIN Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 23: ...e oil filter R R R R R R R R R Fork I I I I I Light aiming operation I I I I I I I I Vehicle general operation I I I I I I I I I Braking systems I I I I I I I I I Lights circuit I I I I I I I I I Safety switches I I I I I I I I I Brake fluid I I I I I I I I I Gearbox oil R R R R R R R R R Fork oil oil seals R R R Engine oil R R R R R R R R R Final drive oil R R R R R R R R R Tyres pressure wear I ...

Page 24: ...E OIL Place a container with 400 cm 25 cu in capacity under the drainage plug 3 Unscrew and remove the drainage plug 3 Unscrew and remove the breather cap 2 Drain the oil into the container allow several minutes for oil to drain out completely Check and if necessary replace the sealing washer of drainage plug 3 Remove any metal scrap attached to the drainage plug 3 magnet Screw and tighten the dra...

Page 25: ...stick 1 Reinsert the dipstick 1 into the opening but do not screw it Remove the dipstick 1 Check oil level on the dipstick 1 The oil level is correct when it close to the MAX mark MAX maximum level MIN minimum level Add engine oil if required Unscrew and remove the dipstick 1 Top up with engine oil until it goes above the minimum level marked MIN CAUTION DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCE...

Page 26: ...Drainage plugs tightening torque 1 12 Nm 1 2 kgm DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT DISPOSE OF ENGINE OIL STORED IN A SEALED CON TAINER AND TAKE IT TO YOUR SUPPLIER OR TO THE NEAREST USED OIL RECLAMATION FIRM Engine oil filter Loosen the screw 3 and remove the cover 4 Remove the engine oil filter 5 NOTE NEVER REUSE A FILTER Spread a thin layer of oil on the sealing ring 6 of the new engine...

Page 27: ...nectors 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 V7 Classic Maintenance MAIN 27 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 28: ...hicle upright so that the fluid in the reservoir is at the same level with the plug Make sure that the fluid level in the reservoir is above the MIN reference mark MIN minimum level MAX maximum level If the fluid does not reach at least the MIN reference mark Check brake pads and disc for wear If the pads and or the disc do not need replacing top up the fluid Maintenance V7 Classic MAIN 28 Revente...

Page 29: ...EEDED TO COMPLETE THE TOPPING UP PROCEDURE TO AVOID SPILLING FLUID WHILE TOPPING UP KEEP THE TANK PARALLEL TO THE RESERVOIR EDGE IN HORIZONTAL POSITION DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO THE FLUID WHEN USING A FUNNEL OR ANY OTHER ELEMENT MAKE SURE IT IS PERFECTLY CLEAN DO NOT EXCEED THE MAX LEVEL MARK WHEN TOP PING UP TOP UP TO MAX LEVEL MARK ONLY WHEN BRAKE PADS ARE NEW WHEN TOPPING UP D...

Page 30: ...Maintenance V7 Classic MAIN 30 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 31: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 32: ...Components arrangement Key 1 Instrument panel 2 Coil 3 Fuel pump Electrical system V7 Classic ELE SYS 32 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 33: ...e criticalities special checks on connections and layouts all this with the aim of obtaining vehicle relia bility Special checks for the correct connection and laying of cables The indicated connectors are considered critical in comparison with the others because the vehicle will stop if they are accidentally disconnected Undoubtedly the connection of the rest of connectors is also important and e...

Page 34: ...STALLATION SECTION FRONT SECTION TABLE A Connect the instrument panel to the main cable harness 1 passing it over the headlight support bracket 2 Clamp the main cable harness to the headlight support bracket with a clamp 3 TABLE B Connect the turn indicators and the temperature sensor to the main system and clamp them as in dicated Electrical system V7 Classic ELE SYS 34 Revente Interdite Revendit...

Page 35: ...dstock Central part 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 SECTION CENTRAL SECTION TABLE A TANK FITTING Place the submersible pump and set the six screws tightening them in a criss cross se q...

Page 36: ...DO NOT SQUEEZE THE TWO TUBES WHILE FASTENING THE CLAMP TABLE C RELAY POSITION 1 Relay with five pins tank side 2 Relay with four pins in third position TABLE D FASTENING THE ELECTRICAL SYSTEM TO THE CHASSIS Position the electrical system on the chassis hold ing the red strap at the centre of the rear coil and fix with a clamp WARNING THE CLAMP MUST BE POSITIONED BEHIND THE REAR COIL SO THAT THE SY...

Page 37: ...generator system regulator system horn system and left ca ble of the chassis cross member CAUTION DO NOT SQUEEZE THE TWO TUBES WHILE FASTENING THE CLAMP TABLE G TIMING SWITCH SYSTEM POSI TION Clamp the timing sensor connector to the left hand side of the chassis positioning it as far as possible from the coil and the spark plug cables V7 Classic Electrical system ELE SYS 37 Revente Interdite Reven...

Page 38: ...iring diagram Key 1 Multiple connectors 2 Revolution sensor 3 Oil pressure sensor 4 Left coil Electrical system V7 Classic ELE SYS 38 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 39: ...attery 21 Starter motor 22 Main fuses 23 Auxiliary fuses 24 License plate light 25 Right rear turn indicator 26 Tail light Stop bulb 27 Rear light 28 Right rear turn indicator 29 Key switch 30 Front stop switch 31 Rear stop switch 32 Right light switch 33 Left light switch 34 Horn 35 Clutch switch 36 Start up relay 37 Light relay 38 39 40 Diode 41 Gear in neutral switch 42 Fall sensor V7 Classic E...

Page 40: ...ky blue B blue Bi white G yellow Gr grey M brown N black R red Ro pink V green Vi purple Checks and inspections Dashboard Service warning light reset The system displays the function as follows the word MAInt is shown on the left LCD Display 1 after the mileage corresponding to the first servicing or any subsequent servicing is excee ded Electrical system V7 Classic ELE SYS 40 Revente Interdite Re...

Page 41: ... the next mileage for which maintenance is foreseen Start up system check pick up input about 100 A level indicators Petrol pump Input 4A to be measured between pins 1 and 2 with 12V supply voltage Fuel level sensor Resistance 1 4 Ohm to be measured between pins 3 and 4 with fuel level equal to 0 litres Lights list BULBS Specification Desc Quantity Low high beam light halogen 12 V 55 W 60 W H4 V7 ...

Page 42: ...nstrument panel lighting LED Fuses FUSE DISTRIBUTION A High beam low beam lights start up 15 A B Stop lights tail lights horn turn indicators 15 A C From battery to injection permanent power sup ply 3 A D Injection services 15 A E Main fuse 30 A F Battery recharge 30 A Electrical system V7 Classic ELE SYS 42 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 43: ...principle Hall effect sensor a square wave pulse is gener ated with voltage between 12V and approximately 0 6 V Level in wiring diagram Speed sensor Location Sensor on the swingarm left side next to the rear brake calliper connector under right fairing next to the Marelli control unit Pin out V7 Classic Electrical system ELE SYS 43 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkau...

Page 44: ...nuity of the grey white cable harness cable harness side from PIN 2 of the sensor to PIN 17 of the instrument panel connector Check instrument panel PIN 17 If there is no failure after all these checks replace the sensor 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 t...

Page 45: ...able harness if there is continuity check the interruption on the sensor and replace it CAUTION If the electric circuit is short circuited no error is displayed Check the sensor electrical specifications If it is not the correct one replace the sensor If it is the correct one check supply insu lation and ground connection insulation of both cables Carry out the tests from the sensor connector to t...

Page 46: ... open shorted to positive check the injection control unit connector and the sensor connector if they are not OK restore if they are OK check the continuity between PIN 11 of the control unit connector and PIN C of the sensor brown yellow cable if there is not continuity restore the cable harness if there is continuity check continuity of the sensor between PIN A and PIN C if there is not continui...

Page 47: ...nnect to the diagnosis instrument selecting FUEL INJECTION and carry out the operation Throttle positioner autodetection Engine temperature sensor Function it informs the engine temperature to the control unit so as to optimise carburetion and idle check Operation Operating principle NTC type sensor resistance sensor inversely variable with temperature Level in wiring diagram Temperature sensors L...

Page 48: ...d the PIN marked by the orange cable 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 marked by the grey cable of the sensor connector and the vehicle ground connection if there is not continuity restore cable harness if there is continuity it means that the error cause is a short...

Page 49: ...k cable harness side 0 5 V signal AXONE PARAMETERS Air temperature In case of failure the value set by the control unit is 20 C 68 F AXONE ELECTRICAL ERRORS air temperature sensor open circuit shorted to positive shorted to negative Error cause If the circuit is open shorted to positive excessive voltage has been detected at PIN 18 of the control unit connector If shorted to negative voltage equal...

Page 50: ...le harness REMARKS No error is detected if the sensor does not work correctly or the control unit connector or sensor terminals are rusty then check through Axone if the temperature indicated is plausible in relation to the ambient temperature Check also that the sensor electrical characteristics are observed replace the sensor if not OK if it is OK check the sensor connector and the Marelli contr...

Page 51: ...using the lambda probe signal to keep the combustion as close as possible to the stoichiometric value AXONE ELECTRICAL ERRORS Lambda probe Generic error Error cause If shorted to positive excessive voltage battery voltage has been detected at PIN 8 or PIN 2 of the control unit connector Troubleshooting if shorted to positive with key set to ON disconnect the sensor connector and measure PIN 1 volt...

Page 52: ...connection 2 Power supply 12V AXONE PARAMETERS Left cylinder injection time Right cylinder injection time AXONE ACTIVATIONS Left injector Operation for 4 ms 5 times The auxiliary injection relay No 12 in the wiring diagram placed under saddle second relay starting from the front CHECK however the identification of the relay with the colour of the cables is energised for 5 seconds and the grey red ...

Page 53: ...The auxiliary injection relay No 12 in the wiring diagram placed under saddle second relay starting from the front CHECK however the identification of the relay with the colour of the cables is energised for 5 seconds and the blue red cable of the injector is closed to ground for 4 ms per second Disconnect the 4 way connector of the fuel pump to be able to hear the relay and injector activation Th...

Page 54: ...s Location centred under the fuel tank connector on the coils Electrical characteristics Primary winding resistance 550 kΩ 10 Secondary winding resistance 3 kΩ 10 Tube resistance 5 kΏ Pin out 1 Supply batt V 2 Circuit ground connection AXONE PARAMETERS Left coil ignition advance Right coil ignition advance AXONE ACTIVATIONS Left coil The auxiliary injection relay No 12 in the wiring diagram placed...

Page 55: ... No 12 in the wiring diagram placed under saddle second relay starting from the front CHECK however the identification of the relay with the colour of the cables is energised for 5 seconds and the orange blue cable of the coil is closed to ground for 2 ms per second Disconnect the 4 way connector of the fuel pump to be able to hear the relay and injector activation The continuity of the wiring is ...

Page 56: ...ff closed circuit continu ity With engine on open circuit infinite re sistance Pin out Voltage 12V Instrument panel Warning light always off Troubleshooting Check the sensor connector and the instrument panel connector PIN 17 If not OK restore If OK check the continuity of the purple cable between the sensor connector and the in strument panel connector PIN 11 if not OK restore the cable harness i...

Page 57: ...t continuity replace sensor after checking cable harness continuity on the sensor side and correct mechanic position if there is continuity check continuity of the black brown green cable between sensor connector and main injection relay if there is not continuity restore the cable harness if there is continuity replace instru ment panel if the vehicle operation is correct NEUTRAL warning light al...

Page 58: ...p relay oth erwise restore the cable harness The vehicle starts without pulling the clutch lever disconnect the terminals from the sensor and check if the released clutch sensor has continuity between the 2 PINS if there is con tinuity replace the sensor if there is not continuity it means that the purple cable from the sensor PIN to the start up relay is shorted to ground Side stand sensor Functi...

Page 59: ...ensor connector and check that with side stand extended there is not continuity between the 2 PINS If there is continuity replace the sensor if there is not con tinuity disconnect diode 40 and check ground insulation of the green brown cable between sensor and diode Bank angle sensor Function it tells the vehicle position to the control unit Operation Operating principle When the sensor is inverte...

Page 60: ...or in vertical position disconnect the connector and check if there is continuity between the two PINS when the sensor is in vertical position if there is continuity replace the sensor if there is not continuity it means that with key set to ON there is not 12V voltage to the PIN marked by the pink yellow cable restore the cable harness whose pink yellow cable will be shorted to ground Air tempera...

Page 61: ...e decreases replace the in strument panel If voltage continues to be approximately 5V restore the pink cable there is a short circuit at 5V In case there is a short circuit to ground connection of PIN 12 of the instrument panel connector Check the earth insulation of the sensor connector pink cable if there is a connection restore the cable harness if it is earth insulated check that sensor resist...

Page 62: ...relli control unit Engine does not shut off with switch in STOP disconnect the connector and with switch in STOP check if there is continuity between the two grey light blue and red green cables sensor side if there is continuity replace the switch if there is not continuity it means that with KEY ON the red grey cable between switch and main injection relay and or the grey black cable between mai...

Page 63: ...utput 20 Left coil control Power output 21 22 Sensors supply ground Power output 23 Control unit supply ground Power input 24 Control unit supply ground Power input 25 26 Control unit supply 15 Power input Dashboard PIN 1 Right arrow input 2 Set rework input 3 High beam lights input 4 n c 5 n c 6 Rear left arrow output 7 Front left arrow output 8 EFI input 9 Left arrow input 10 Neutral input 11 Oi...

Page 64: ... c 20 Reserve input 21 Key 22 Ground connection 23 Battery 24 Front right arrow output 25 Rear right arrow output 26 Battery Electrical system V7 Classic ELE SYS 64 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 65: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 66: ...el Disconnect the speed sensor connec tion and slide off the cable from the cable harness Remove the swingarm and the bevel gear pair Removing the engine from the vehicle Disconnect the electrical connections of the generator Engine from vehicle V7 Classic ENG VE 66 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 67: ...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 V7 Classic Engine from vehicle ENG VE 67 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 68: ...connect the spark plug cables from the coils and slide them off the chassis Loosen the clamps on the intake mani folds Disconnect the oil breather pipe on the cylinder heads Engine from vehicle V7 Classic ENG VE 68 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 69: ...sensor Disconnect the starter motor and the lambda probe Open the clamp and disconnect the oil breather pipe of the air filter casing V7 Classic Engine from vehicle ENG VE 69 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 70: ... 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 Engine from vehicle V7 Classic ENG VE 70 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 71: ...ews fixing the chassis to the gearbox cover Remove the rod fixing the chassis to the gearbox Remove the engine check that during the removal operation the throttle body sleeves slide off the inlet mani folds without getting damaged Lower the engine checking that it gets correctly detached from the chassis V7 Classic Engine from vehicle ENG VE 71 Revente Interdite Revendita Vietata Resaling Forbide...

Page 72: ... that the throttle body sleeves are inserted correctly on the intake manifolds With the engine in position fit the rod fixing the chassis to the gearbox tightening it to the prescribed torque Tighten to the prescribed torque the upper screws fixing the chassis to the gearbox cover Fasten the chassis front arms to the engine cradle using the four Allen head screws Tighten them to the prescribed tor...

Page 73: ...ion 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 V7 Classic Engine from vehicle ENG VE 73 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 74: ...e the connection of the engine temperature sensor Insert the breather pipes on the cylin der heads and lock them with the spe cific clamps Engine from vehicle V7 Classic ENG VE 74 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 75: ...ors in their positions and fit the locking ring tightening the screw to the prescribed torque Connect the spark plug cables on the ignition coils V7 Classic Engine from vehicle ENG VE 75 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 76: ...rt the pin on the engine block locking it with the corresponding split pin Refit the swingarm and the bevel gear pair Engine from vehicle V7 Classic ENG VE 76 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 77: ...ews to the prescribed torque Restore the electrical connections of the generator Restore the connection of the vehicle speed sensor V7 Classic Engine from vehicle ENG VE 77 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 78: ...INDEX OF TOPICS POWER SUPPLY P SUPP Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 79: ...iagram Key 1 Fuel tank 2 Throttle body 3 Fuel filter 4 Fuel delivery pipe 5 Fuel pump unit Injection V7 Classic Power supply P SUPP 79 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 80: ...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 Power supply V7 Classic P SUPP 80 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 81: ...ter pipes to the relative joints The Axone should display the setting up adjustments screen page Make sure the throttle valve is fully in Autodetect the throttle position Turn the key to OFF and leave it for at least 30 seconds DO NOT TOUCH THE THROTTLE ABUTMENT SCREW OR THE THROTTLE BODY MUST BE RE PLACED CHECK THAT THE THROTTLE RETURN CABLE IS NOT TAUT V7 Classic Power supply P SUPP 81 Revente I...

Page 82: ... vacuometer To correct compensation use the set screw of the control rod of the throttle bodies on the left side of the vehicle until cylinders are compensated Now it is necessary to adjust idle speed Take the engine to the prescribed temperature 70 80 C 158 176 F Operating the by pass screws adjust idle 1100 50 rpm Power supply V7 Classic P SUPP 82 Revente Interdite Revendita Vietata Resaling For...

Page 83: ...SCREEN PAGE Specification Desc Quantity Throttle Value corresponding to the throttle when closed approximate value between 4 5 and 4 9 left throttle supported by the end of stroke screw If a different value is read it is necessary to activate the parameter Throttle positioner autodetection and obtain this value TPS Trimmer Supplementary parameter related to throttle keying in calibra tion Precise ...

Page 84: ...vance Atmospheric pressure 1015 mPa approximate values The sensor is inside the instrument panel Air temperature C Temperature of the air taken in by the engine measured by the sensor in the filter casing This is not the temperature indicated by the instrument panel Engine temperature C Battery voltage V Device status screen page DEVICE STATUS This screen page shows the status usually ON OFF of th...

Page 85: ... Quantity Engine temperature Possible short circuit in the earth lead battery or open circuit Left coil Possible short circuit in the earth lead battery or open circuit If both coils do not work the engine does not work Right coil Possible short circuit in the earth lead battery or open circuit If both coils do not work the engine does not work Left injector Possible short circuit in the earth lea...

Page 86: ...rth connections RPM sensor Adjustable parameters screen page ADJUSTABLE PARAMETERS This screen page is used to adjust some control unit parameters ADJUSTABLE PARAMETERS Specification Desc Quantity Throttle positioner autodetection Allows the control unit to detect the closed throttle position just press the enter button Self adjustable parameters reset Reset the self adjustable parameters of the l...

Page 87: ...INDEX OF TOPICS SUSPENSIONS SUSP Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 88: ...t 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 Screw 2 Washer Suspensions V7 Classic SUSP 88 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 89: ...mplete cap 18 Screw 19 Base with headstock 20 Ring nut 21 Fork upper plate 22 Washer 23 Nut 24 Rubber ring 25 Spacer 26 Cap 27 Nut 28 Ring 29 Complete right sleeve 30 Lower U bolt 31 Upper U bolt 32 Screw 33 Screw 34 O ring 35 Stem protection 36 Chrome plated cap 37 Gasket kit 38 Oil seal kit V7 Classic Suspensions SUSP 89 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verbote...

Page 90: ...ERNAL COMPO NENTS SHOULD BE TIGHTENED ON A VICE MAKE SURE NOT TO DAMAGE THEM BY OVER TIGHTENING ALWAYS USE ALUMINIUM JAW CAPS Remove the front wheel Remove the front mudguard Undo and remove the two screws and collect the washers Move the instrument panel forwards Undo the upper sealing screw Suspensions V7 Classic SUSP 90 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verbote...

Page 91: ...e 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 Unscrew the upper closing cap Pay attention to the possible thrust that the spring can cause to the loosened cap V7 Classic Suspensions SUSP 91 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 92: ...tem and make sure that there are no dam aged elements If there are no damaged or worn ele ments refit the stem otherwise re place the damaged elements 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 Disassembling the fork Drain all the oil from the stem Block the wheel holder fork leg on the vice Undo the bottom screw and r...

Page 93: ...LEG RIM Slide off the bearing tube from the wheel holder fork leg together with the sealing ring the cap the upper bush ing and lower bushings NOTE WHEN REMOVING THE PIPE FROM THE WHEEL HOLDER FORK LEG SOME PARTS MAY REMAIN INSIDE THE FORK LEG IF THIS OCCURS THESE PARTS MUST BE RE MOVED AFTERWARDS BEING CAREFUL NOT TO DAM AGE THE FORK LEG RIM AND THE UPPER BUSHING SEAT V7 Classic Suspensions SUSP ...

Page 94: ... unit from the holding tube if it is damaged replace the counter spring and the ring 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 Check that the upper guide bushing is fitted on the wheel holder f...

Page 95: ...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 V7 Classic Suspensions SUSP 95 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 96: ...be 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 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 Suspensions V7 Classic SUSP 96 Revente Interdite Revendita Vietata Resaling ...

Page 97: ...imes Measure the air gap between the oil level and the rim THE SLEEVE MUST BE PERFECTLY UPRIGHT IN ORDER TO MEASURE THE CORRECT OIL LEVEL THE OIL LEVEL MUST BE THE SAME IN BOTH STEMS Characteristic Oil level from sleeve rim without the spring and with stem at the end of the stroke 150 mm 5 9 in Introduce the spring and the preload tube V7 Classic Suspensions SUSP 97 Revente Interdite Revendita Vie...

Page 98: ...he 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 Suspensions V7 Classic SUSP 98 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 99: ...o 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 Unscrew and remove the central nut Remove the upper plate from the front fork V7 Classic Suspensions SUSP 99 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 100: ...e 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 Suspensions V7 Classic SUSP 100 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 101: ...Removing Undo and remove the upper screw Undo and remove the lower screw V7 Classic Suspensions SUSP 101 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 102: ...INDEX OF TOPICS CHASSIS CHAS Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 103: ...r 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 V7 Classic Chassis CHAS 103 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 104: ...and col lect the washer Loosen the wheel pin locking screw Remove the wheel pin and collect the spacer Remove the rear wheel Chassis V7 Classic CHAS 104 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 105: ...imming washer be tween the swingarm right arm and the gearbox Checking Check that the universal joint is not damaged the gear teeth inserting in the sleeve grooves and the grooves on the joint are not deformed or damaged otherwise replace the joint V7 Classic Chassis CHAS 105 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 106: ... still flexible and is not deformed Check that the sleeve outer toothing and internal grooves are not damaged Installing Insert the swingarm on the gearbox cover Tighten thoroughly the pin on the left side until the shimming washer on the right side rests on the bearing fitted on the gearbox cover Tighten thoroughly the pin on the right side without locking it Operate the swingarm and make sure it...

Page 107: ...ear wheel Bevel gears Removing Undo the four nuts and collect the washers Slide off the gearcase together with the swingarm V7 Classic Chassis CHAS 107 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 108: ... the base Slide off the gear Checking Pinion unit Remove the housing of the swingarm Slide the complete case of the gear case Lock on the vice the sealing tool 19907100 of the bevel gear pair Chassis V7 Classic CHAS 108 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 109: ...ol 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 V7 Classic Chassis CHAS 109 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 110: ... damaged that the rollers are not damaged or worn otherwise replace them Check that the adjustment washers are not deformed or broken otherwise replace them Check that the sealing rings are not shattered spoiled or worn otherwise replace them Fitting If the bevel pinion should be replaced replace also the crown fitted on the housing The pinion and the crown should have the same number stam ped Cha...

Page 111: ... 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 V7 Classic Chassis CHAS 111 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 112: ... 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 Chassis V7 Classic CHAS 112 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 113: ...Remove the braking disc from the dril led bolt Undo the screws and collect the plates and the wave washers Slide off the complete cover Slide off the gaskets Slide off the shimming ring Remove the O ring from the groove on the drilled bolt V7 Classic Chassis CHAS 113 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 114: ... a suitable punch 19907000 Remove the washer Remove the washer Undo the screws and collect the corre sponding safety plates Remove the conical crown Slide off the drilled bolt from the bear ing Chassis V7 Classic CHAS 114 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 115: ...table extractor 19927500 Remove the sealing ring and the wash er Checking Check that the drilled bolt tongues where the anti vibration rubbers operate are not spoiled that the surfaces of the sealing ring the bearing on the cover the external ring of the bearing V7 Classic Chassis CHAS 115 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 116: ...r distorted Crown pinion coupling For coupling proceed as follows Provisionally lock the complete pinion case on the housing with two nuts and appropriate spacers Fit the corresponding tool on the crown 19928800 Insert the tool on the bearing cage in the housing Check alignment between pinion teeth and the crown teeth If alignment is not regular properly vary the thickness of the ring between the ...

Page 117: ...pro priate central spacers slightly presses the crown towards the brake disc side Turn the pinion in the riding direction with the crown braked so that the rota tion is carried out under load and leaves a contact mark on the pinion surface If the contact is regular the mark on the pinion teeth will be like this the pinion is seen from the crankshaft side V7 Classic Chassis CHAS 117 Revente Interdi...

Page 118: ...ion by reducing spacer thickness If the contact is like this the pinion is too far from the rotation axis of the crown approach the pinion by increas ing spacer thickness If the contact is like this the crown is too far from the pinion rotation axis ap proach the crown by reducing spacer thickness Casing unit fitting Chassis V7 Classic CHAS 118 Revente Interdite Revendita Vietata Resaling Forbiden...

Page 119: ...e 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 V7 Classic Chassis CHAS 119 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 120: ...n 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 Chassis V7 Classic CHAS 120 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 121: ... 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 V7 Classic Chassis CHAS 121 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 122: ...smission 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 Installing Insert the sleeve and base on the bevel pinion of the gearcase Chassis V7 Classic CHAS 122 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 123: ... the stud bolts of the gearcase in the holes of the swingarm Screw the nuts with the washers with out locking them V7 Classic Chassis CHAS 123 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 124: ... 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 18 Silencer fixing bushing 19 Nut Chassis V7 Classic CHAS 124 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 125: ...f Before handling these components make sure that you are wearing insulating gloves or wait until the engine and the exhaust system have cooled down Loosen the clamp between the ex haust end and the catalytic converter Unscrew and remove the silencer fix ing nut and collect the screw and the bushing Remove the exhaust end Removing the lambda sensor Disconnect the lambda probe connec tor V7 Classic...

Page 126: ... Unscrew and remove the lambda probe Chassis V7 Classic CHAS 126 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 127: ...INDEX OF TOPICS BODYWORK BODYW Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 128: ...screw Disconnect the connector Disconnect the fuel pipe Remove the fuel bleeding pipe Remove the fuel tank by sliding it off and back Bodywork V7 Classic BODYW 128 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 129: ...INDEX OF TOPICS PRE DELIVERY PRE DE Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 130: ...Main switch Headlamps high beam lights low beam lights tail lights front and rear and their warning lights Headlight adjustment according to regulations in force Front and rear stop light switches and their bulbs Turn indicators and their warning lights Instrument panel lights Instrument panel fuel and temperature indicator if present Instrument panel warning lights Horn Electric start up Engine s...

Page 131: ...ASH WITH ABUNDANT WATER FOR AP PROX 15 MIN AND SEEK IMMEDIATE MEDICAL ATTENTION IF ACCIDENTALLY SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL SEEK IMMEDIATE MEDICAL ATTENTION BATTERIES PRODUCE EXPLOSIVE GASES KEEP CLEAR OF NAKED FLAMES SPARKS OR CIGARETTES VENTILATE THE AREA WHEN RECHARGING INDOORS ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES KEEP ...

Page 132: ... braking system Stroke of brake and clutch levers if present Clutch Check for correct operation Engine Check for correct general operation and absence of abnormal noise Other Documentation check Chassis and engine numbers check Supplied tools check License plate fitting Locks checking Tyre pressure check Installation of mirrors and any possible accessories NEVER EXCEED THE RECOMMENDED INFLATION PR...

Page 133: ...88 90 92 94 98 Fuel 128 Fuses 42 I Identification 10 Instrument panel 60 M Maintenance 8 23 O Oil filter 26 R Recommended products 18 S Shock absorbers 100 Spark plugs Stand 58 Start up 41 T Tank 128 Transmission 12 23 Tyres 14 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 134: ...W Warning lights Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

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