MOTO GUZZI V7 II ABS Page 100 Service Station Manual Download

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restore them. If there is, PIN 2 of the sensor on the cable harness side, with the sensor disconnected

and key set to ON, must have 12V voltage approximately: if there is no voltage, check PIN 2 for continuity

with the vehicle ground connection: if it is grounded, restore the cable harness. If OK, replace the control

unit. If PIN 2 has approx. 12 V, check the continuity of the white cable between PIN 1 of the sensor on

the cable harness side and PIN 13 of the ABS control unit connector. If there is no continuity, restore

the cable harness. If there is, replace the logic errors sensor.

LOGIC ERRORS

Speed sensor

5D91 the signal works irregularly:

faulty sensor or signal interference.

Troubleshooting:

Check speed sensor retainer. If it is not OK, restore it. If it is OK, check if the tone

wheel is dirty, deformed or wrongly fixed. If any of this happens, replace the tone wheel. Otherwise,

replace the speed sensor.

5D92 the signal decreases periodically:

Possible tone wheel fault due to deformations or dirt; pos-

sible alterations on the wheel bearing surface. 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. If it is OK, check for possible faults in the wheel bearings and if it is not OK, replace the

bearings.

5D93 missing signal or speed measured too low in relation to the rear wheel:

faulty sensor or

missing sensor/tone wheel. Or excessive distance between the sensor and the tone wheel or tone wheel

with wrong number of teeth.

Troubleshooting:

Check that the speed sensor and the tone wheel are installed. If they are not, install

them. If they are, check the speed sensor retainer. 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. If it is not OK, replace

the tone wheel and if it is OK, replace the speed sensor.

5D94 no acceleration after pressure reduction:

Faulty sensor or missing sensor/tone wheel or ex-

cessive distance between the sensor and the tone wheel.

Troubleshooting:

Check that the speed sensor and the tone wheel are installed. If they are not, install

them. If they are, check the speed sensor retainer. 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. If it is not OK, replace

the tone wheel and if it is OK, replace the speed sensor.

5D95 excessive speed measured:

Faulty sensor or tone wheel, or tone wheel with wrong number of

teeth or wrong tyre size.

Troubleshooting:

Check that the speed sensor and the tone wheel are installed. If they are not, install

them. If they are, check the speed sensor retainer. 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. If it is not OK, replace

the tone wheel and if it is OK, check that the tyre size is the correct one. If it is not OK, replace it. If it is

Electrical system

V7 II ABS

ELE SYS - 100

Summary of Contents for V7 II ABS

Page 1: ...SERVICE STATION MANUAL 2Q000105 V7 II ABS ...

Page 2: ...riginal spare parts undergo quality control procedures to guarantee reliability and durability The descriptions and images in this publication are given for illustrative purposes only and are not binding While the basic characteristics as described and illustrated in this booklet remain unchanged Piaggio C S p A reserves the right at any time and without being required to update this publication b...

Page 3: ...hanges in repair procedures are communicated 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 an...

Page 4: ......

Page 5: ...ERISTICS CHAR SPECIAL TOOLS S TOOLS MAINTENANCE MAIN ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG POWER SUPPLY P SUPP SUSPENSIONS SUSP CHASSIS CHAS BRAKING SYSTEM BRAK SYS BODYWORK BODYW PRE DELIVERY PRE DE ...

Page 6: ...INDEX OF TOPICS CHARACTERISTICS CHAR ...

Page 7: ...CONTACT WITH NAKED FLAMES SPARKS OR OTHER SOURCES WHICH MAY CAUSE THEM TO IGNITE OR EXPLODE DO NOT DISPERSE FUEL IN THE ENVIRONMENT KEEP OUT OF THE REACH OF CHILDREN Hot components The engine and the exhaust system components become very hot and remain hot for some time after the engine has been switched off When handling these components wear insulating gloves or wait until the engine and the exh...

Page 8: ...ATELY THE BATTERY RELEASES EXPLOSIVE GASES KEEP IT AWAY FROM FLAMES SPARKS CIGARETTES OR ANY OTHER HEAT SOURCES ENSURE ADE QUATE VENTILATION WHEN SERVICING OR RECHARGING THE BATTERY KEEP OUT OF THE REACH OF CHILDREN BATTERY LIQUID IS CORROSIVE DO NOT POUR IT OR SPILL IT PARTICULARLY ON PLASTIC COMPONENTS ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BAT TERY TO BE ACTIVATED Maintenance ...

Page 9: ...before refitting them Smear a light layer of lithium based grease on the oil guard rims Reassemble oil guards and bearings with the brand or lot number facing outward visible side ELECTRIC CONNECTORS Electric connectors must be disconnected as described below failure to comply with this procedure causes irreparable damage to both the connector and the wiring harness Press the relevant safety hooks...

Page 10: ...ISAPPEAR 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 THE FULL PERFORMANCE OF THE VEHICLE IS ONLY AVAILABLE AFTER THE SERVICE AT THE END OF THE RUNNING IN PERIOD Follow these guidelines Do not twist the throttle grip abruptly and completely when the engine is working at a low revs either during or af...

Page 11: ...er is stamped on the left side close to the engine oil level check cap Dimensions and mass WEIGHT AND DIMENSIONS Specification Desc Quantity Max length V7 Special V7 Stone V7 Racer 2185 mm 86 02 in Max length V7 Stornello 2240 mm 88 19 in Max length V7 Special V7 Stone V7 Stornello 800 mm 31 50 in Max width V7 Racer 740 mm 29 13 in Max height V7 Special V7 Stone V7 Racer 1115 mm 43 90 in Max heigh...

Page 12: ...gear 24 26 1 1 083 Gear ratios 5th gear 25 24 1 0 96 Gear ratios 6th gear 27 24 1 0 888 Final drive with cardan shaft ratio 8 33 1 4 125 Capacities CAPACITY Specification Desc Quantity Fuel tank reserve included 21 l 4 62 UKgal 5 55 US gal Fuel tank reserve 4 l 0 88 UKgal 1 06 US gal Engine oil Oil change and oil filter replacement 2000 cm 122 05 cu in Gearbox oil 500 cm 30 51 cu in Transmission o...

Page 13: ... Engine oil pressure LED MI warning light LED ABS Warning Light LED MGCT warning light LED Frame and suspensions FRAME Specification Desc Quantity Type Modular double cradle high strength steel tubular chassis Steering rake 27 5 Trail 117 mm 4 61 in SUSPENSIONS Specification Desc Quantity Front hydraulic telescopic fork Ø 40 mm 1 57 in Stroke 137 mm 5 39 in Rear V7 Special V7 Stone V7 Stornello Sw...

Page 14: ...irelli Sport Demon Front standard 100 90 18 56H Front alternative measures V7 Stornello 100 90 V18 56V Front inflation pressure V7 Special V7 Stone V7 Racer 2 5 bar 250 kPa 36 26 PSI Front inflation pressure V7 Stornello 2 4 bar 240 kPa 34 81 PSI Front inflation pressure with passenger V7 Special V7 Stone V7 Racer 2 6 bar 260 kPa 37 71 PSI Front inflation pressure with passenger V7 Stornello 2 4 b...

Page 15: ...ification Desc Quantity Type Electronic injection Marelli MIU G3 Diffuser Ø 38 mm 1 50 in Fuel Premium unleaded petrol minimum octane rating of 95 NORM and 85 NOMM Tightening Torques Chassis V7 II ABS Characteristics CHAR 15 ...

Page 16: ...p 1 1 50 Nm 36 88 lb ft 2 Calliper bracket fixing screws M6x30 2 10 Nm 7 38 lb ft 3 Screws fixing fork stanchions to upper and low er plate M10x40 2 2 50 Nm 36 88 lb ft 4 Headstock fixing ring nut M25x1 1 7 Nm 5 16 lb ft The fork must fall to one side by itself Characteristics V7 II ABS CHAR 16 ...

Page 17: ... bolt fastener screws M8x30 2 2 25 Nm 18 44 lb ft 7 Screws fixing handlebar support U bolts to steering plate M10x60 2 50 Nm 36 88 lb ft INSTRUMENT PANEL pos Description Type Quantity Torque Notes 1 Screw fixing instrument panel and headlamp support M6 3 3 8 Nm 5 90 lb ft V7 II ABS Characteristics CHAR 17 ...

Page 18: ...Manual Gas covers fastener screw M5 3 6 Nm 4 43 lb ft HANDLEBAR AND CONTROLS pos Description Type Quantity Torque Notes 1 Switch fastener screw SWP 5 1 1 1 5 Nm 1 11 lb ft 2 Semi handlebar fixing screw M6x25 4 10 Nm 7 38 lb ft 3 Counterweight fixing screw M6 2 10 Nm 7 38 lb ft Loctite 243 4 Screw fastening the clutch control U bolt to the semi handlebar M6 2 10 Nm 7 38 lb ft 5 Mirror fixing M10 1 ...

Page 19: ...tity Torque Notes 1 Brake pump U Bolt fixing screw M6 2 10 Nm 7 38 lb ft 2 Front brake calliper fixing screw M10x30 2 50 Nm 36 88 lb ft 3 Fixing screw for brake fluid pipe on pump and calliper 2 25 Nm 18 44 lb ft V7 II ABS Characteristics CHAR 19 ...

Page 20: ...os Description Type Quantity Torque Notes 1 Screw fastening stabiliser plate to fork M8x40 4 15 Nm 11 06 lb ft Loctite 243 2 Screw fastening mudguard to stabiliser plate Special Stone Racer M6x11 4 10 Nm 7 38 lb ft Loctite 243 2 Screw fastening mudguard to stabiliser plate Stornello M6x16 4 8 Nm 5 90 lb ft Loctite 243 3 Top fairing fixing screw Racer M6 2 10 Nm 7 38 lb ft 3 Fixing screw of windshi...

Page 21: ...eel axle M18x1 5 1 80 Nm 59 00 lb ft 2 Front brake disc fixing screw M8x20 6 25 Nm 18 44 lb ft Loctite 243 3 ABS sensor fixing stud bolt M5 1 6 Nm 4 43 lb ft Loctite 243 4 Cable grommet retainer nut M6 1 10 Nm 7 38 lb ft Central part V7 II ABS Characteristics CHAR 21 ...

Page 22: ... gearbox to frame M10x55 2 50 Nm 36 88 lb ft 4 Pin fixing engine gearbox to chassis M10 1 50 Nm 36 88 lb ft 5 Battery supporting plate fixing screw M8x16 4 25 Nm 18 44 lb ft 6 Screw fixing license plate holder arc to chassis Stornello M8 2 2 25 Nm 18 44 lb ft 6 Screw fixing exhaust silencer mount ing to frame Special Stone Racer M8x16 4 25 Nm 18 44 lb ft Loctite 243 Characteristics V7 II ABS CHAR ...

Page 23: ...Quantity Torque Notes 1 Screw fixing stand beam to cradle M10 1 50 Nm 36 88 lb ft 2 Screw fastening cradle to frame M10 2 50 Nm 36 88 lb ft 3 Pin fixing engine gearbox to chassis M10 1 50 Nm 36 88 lb ft V7 II ABS Characteristics CHAR 23 ...

Page 24: ...ntity Torque Notes 1 Pedal rubber fastening screw M6x12 4 10 Nm 7 38 lb ft 2 Screw fastening rider footrest mounting to frame M8 2 2 25 Nm 18 44 lb ft Loct 243 3 Lever peg fixing M6 1 10 Nm 7 38 lb ft Loct 243 Characteristics V7 II ABS CHAR 24 ...

Page 25: ...M8 1 20 Nm 14 75 lb ft Loctite 243 RIDER FOOTREST GEAR SHIFT LEVER pos Description Type Quantity Torque Notes 1 Screw fastening left hand rider foot rest mounting plate to cradle M8x20 2 25 Nm 18 44 lb ft Loctite 243 2 Preselector lever fixing screw M6x20 1 10 Nm 7 38 lb ft 3 Gearbox lever fixing screws M6x20 1 10 Nm 7 38 lb ft Loctite 243 4 Gearbox control rod fixing nut M6x1 1 10 Nm 7 38 lb ft L...

Page 26: ...Notes 1 Nut fixing rear brake lever M8 1 20 Nm 14 75 lb ft 2 Rear brake fluid reservoir fixing screw M5x15 1 3 Nm 2 21 lb ft 3 Rear brake rod fixing lock nut M6 1 Manual 4 Brake pump fixing screws M6x25 2 10 Nm 7 38 lb ft Characteristics V7 II ABS CHAR 26 ...

Page 27: ... ing to plate M8 1 25 Nm 18 44 lb ft Loctite 243 4 Rear brake pump fixing screw M6x25 2 8 Nm 5 90 lb ft Loctite 243 5 Rear brake fluid reservoir fixing screw M5x15 1 6 Nm 4 43 lb ft 6 Nut fastening rod terminal on brake lever M6 1 10 Nm 7 38 lb ft SIDE STAND pos Description Type Quantity Torque Notes 1 Side stand retainer pin M10x1 2 5 1 10 Nm 7 38 lb ft 2 Lock nut for stand bolt M10x1 2 5 1 30 Nm...

Page 28: ...FUEL TANK pos Description Type Quantity Torque Notes 1 Rear tank fixing screw M8 1 25 Nm 18 44 lb ft 2 Screw fastening cap flange to tank M4 5 3 Nm 2 21 lb ft Characteristics V7 II ABS CHAR 28 ...

Page 29: ...tes 1 Fuel pump support fixing screw to the tank M5x16 6 5 Nm 3 69 lb ft Screws fixing sleeve to cylinder head M6 2 2 10 Nm 7 38 lb ft Screw washer fixing on sleeve M6 2 8 Nm 5 90 lb ft Clamp fastening screw 2 3 Nm 2 21 lb ft V7 II ABS Characteristics CHAR 29 ...

Page 30: ... Nm 2 21 lb ft 2 Air filter box cover fastening screw SWP 5x14 4 3 Nm 2 21 lb ft BODYWORK CENTRAL SECTION SADDLE pos Description Type Quantity Torque Notes 1 Saddle release block fixing screw M6x25 2 10 Nm 7 38 lb ft 2 Side fairing fixing screw M5x9 2 4 Nm 2 95 lb ft Characteristics V7 II ABS CHAR 30 ...

Page 31: ...6x25 2 10 Nm 7 38 lb ft 2 Throttle body cover fastener screw M5x14 4 4 Nm 2 95 lb ft 3 Side fairing fixing screw M5x9 6 4 Nm 2 95 lb ft BODYWORK CENTRAL SECTION SADDLE pos Description Type Quantity Torque Notes 1 Saddle release block fixing screw Stornello M5x12 2 5 Nm 3 69 lb ft V7 II ABS Characteristics CHAR 31 ...

Page 32: ...airing M6 2 2 5 Nm 3 69 lb ft 5 Throttle body cover fastener screw M6 1 1 4 Nm 2 95 lb ft Loctite 243 Throttle body cover support fastener screw M6 1 1 10 Nm 7 38 lb ft LOCK KIT pos Description Type Quantity Torque Notes 1 Shear head screw fixing ignition lock M8x15 1 At the point of failure 2 Ignition lock fixing screw M8x16 1 25 Nm 18 44 lb ft Characteristics V7 II ABS CHAR 32 ...

Page 33: ...0 Nm 7 38 lb ft 3 Compensator fixing clamp screw to the silencer M6 2 10 Nm 7 38 lb ft 4 Lambda probe on compensator M18x1 5 1 38 Nm 28 03 lb ft 5 Nut fastening silencer to mounting plate M8 4 25 Nm 18 44 lb ft 6 Heat shield fixing screw M6x12 6 10 Nm 7 38 lb ft Loctite 270 7 Screw fixing silencer mounting plate to frame M8x40 2 25 Nm 18 44 lb ft V7 II ABS Characteristics CHAR 33 ...

Page 34: ...llo M6 1 10 Nm 7 38 lb ft 2 Lambda probe fastener M18x1 5 1 1 38 Nm 28 03 lb ft 3 Heat shield fixing screw M6 2 2 8 Nm 5 90 lb ft Loctite 270 4 Fixing silencer support to chassis screw nut M8 2 2 25 Nm 18 44 lb ft Exhaust pipe fixing nut to the engine M6 2 2 10 Nm 7 38 lb ft Characteristics V7 II ABS CHAR 34 ...

Page 35: ...rque Notes 1 Swingarm clamp retaining screw M10x45 1 30 Nm 22 13 lb ft 2 Pin fixing the rear calliper holding plate to swingarm M16x1 1 35 Nm 25 81 lb ft 3 Nut fixing gearcase to swingarm M8 4 25 Nm 18 44 lb ft Hold the stud bolt 4 Pin fixing swingarm to gearbox M20x1 2 Fully home with no preload 5 Lock nut on swingarm pin M20x1 2 50 Nm 36 88 lb ft Hold the pin V7 II ABS Characteristics CHAR 35 ...

Page 36: ...2 10 Nm 7 38 lb ft Loctite 243 2 Lower pin fastening left shock absorber to swingarm M10x1 5 1 35 Nm 25 81 lb ft 3 Stud bolt fixing right shock absorber to rear box M12x1 5 1 35 Nm 25 81 lb ft 4 Screw fastening right shock absorber to stud bolt M6x18 1 10 Nm 7 38 lb ft Loctite 243 Characteristics V7 II ABS CHAR 36 ...

Page 37: ...pos Description Type Quantity Torque Notes 1 Pedal rubber fastening screw M6x12 4 10 Nm 7 38 lb ft 2 Screw fastening passenger footrest mounting to frame M8 2 2 25 Nm 18 44 lb ft Loct 243 V7 II ABS Characteristics CHAR 37 ...

Page 38: ... 1 100 Nm 73 76 lb ft 2 Rear brake disc fixing screw M8x25 6 25 Nm 18 44 lb ft Loctite 243 3 ABS sensor support fixing screw M6 2 10 Nm 7 38 lb ft 4 ABS sensor fixing screw M5 1 6 Nm 4 43 lb ft Loctite 243 REAR BRAKE CALLIPER pos Description Type Quantity Torque Notes 1 Rear brake calliper fixing screw M8x30 2 25 Nm 18 44 lb ft Drilled screw for brake pipe on cal liper 1 25 Nm 18 44 lb ft Characte...

Page 39: ...GHTS pos Description Type Quantity Torque Notes 1 Screw fastening taillight support to mudguard M5x14 3 4 Nm 2 95 lb ft 2 Rear turn indicator fixing screw M6 2 5 Nm 3 69 lb ft V7 II ABS Characteristics CHAR 39 ...

Page 40: ...UNTING pos Description Type Quantity Torque Notes 1 Retroreflector support fixing screw to the license plate M5x10 2 4 Nm 2 95 lb ft 2 Retroreflector fixing nut retainer to the support M5 1 4 Nm 2 95 lb ft Characteristics V7 II ABS CHAR 40 ...

Page 41: ... lb ft 2 Rear mudguard fixing screw Stornello M6 4 8 Nm 5 90 lb ft 3 Screw fixing license plate holder to mudguard reinforcement Special Stone Racer SWP M5x20 3 3 Nm 2 21 lb ft ELECTRICAL SYSTEM 01 pos Description Type Quantity Torque Notes 1 Speed sensor fastening screw M6 1 10 Nm 7 38 lb ft 2 Coil retainer nut M6 2 2 10 Nm 7 38 lb ft Voltage regulator fixing screw M6 2 10 Nm 7 38 lb ft Control u...

Page 42: ...Specifications ENI i RIDE PG 10W 60 Lubricant formulated with advanced syn thetic technology and high performance additives to cater specifically for 4 stroke engines with high specific power outputs JASO MA MA2 API SG AGIP GEAR MG SAE 85W 140 Transmission oil API GL 4 and GL 5 ENI ROTRA LSX 75W 90 Gearbox oil API GL 5 AGIP FORK 7 5W Fork oil SAE 5W SAE 20W AGIP GREASE SM 2 Gray black smooth textu...

Page 43: ...BRAKE 4 Brake fluid SAE J 1703 FMVSS 116 DOT 3 4 ISO 4925 CUNA NC 956 DOT 4 synthetic fluid NOTE USE ONLY NEW BRAKE FLUID DO NOT MIX DIFFERENT BRANDS OR TYPES OF OIL WITHOUT CHECKING THEIR BASE COMPATIBILITY V7 II ABS Characteristics CHAR 43 ...

Page 44: ...INDEX OF TOPICS SPECIAL TOOLS S TOOLS ...

Page 45: ...92 88 00 Bevel gear set alignment pre fitting tool 19 92 60 00 Punch for gearcase sealing ring 19 90 70 00 Extractor for internal ring on drilled bolt 19 92 75 00 Extractor for external ring of gearcase bearing 19 92 62 00 Punch for bearing on bevel gear set pin ion V7 II ABS Special tools S TOOLS 45 ...

Page 46: ...ch for external ring of tapered bearing on bevel gear set 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 Special tools V7 II ABS S TOOLS 46 ...

Page 47: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 48: ... x 1 000 mi x 1 000 1 0 6 10 6 2 20 12 4 30 18 6 40 24 9 50 31 1 60 37 3 Spark plugs R R R R R R Transmission cables and controls I I I I I I I Steering bearings and steering clearance I I I I I I I Wheel bearings I I I I I I Diagnosis by tool I I I I I I I Brake discs I I I I I I I Air filter R R R R R R Oil filter change C C Engine oil filter R R R R R R R Lights operation aiming I I I I I I Veh...

Page 49: ... I I I I I I Light circuit I I I I I I I Safety switches I I I I I I I Brake fluid 2 I I I I I I I Gearbox oil R R Fork oil 8 R Engine oil 6 R R R R R R R Final drive oil R R R R Fork oil seal 1 I I I I I I Tyres pressure wear 5 I I I I I I I Valve clearance adjustment A A A A A A A Wheels I I I I I I I Bolts and nuts tightening I I I I I I I Battery terminals tightening I Head screws tightening A...

Page 50: ...OTE RIDE SOME km miles TO WARM UP ENGINE 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 ...

Page 51: ...FTER RUNNING FOR ABOUT 15 KM 10 miles Switch off the engine and wait at least five minutes to allow the lubricant to drain back into the sump Keep the vehicle upright with both wheels on the ground Unscrew and remove the cap with dipstick Clean dipstick Refit the cap with dipstick into its hole without tightening Remove the cap with dipstick Check oil level by means of the oil dipstick The oil lev...

Page 52: ...rew and tighten the drainage plugs 1 Tightening torque for drainage plugs 1 12 Nm 8 85 lb ft DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT DISPOSE OF ENGINE OIL IN A SEALED CONTAINER AND TAKE IT TO YOUR SUPPLIER OR TO THE NEAREST USED OIL COLLECTION CENTRE Engine oil filter Undo the two screws 3 and remove the cover 4 Remove the engine oil filter 5 NOTE NEVER REUSE AN OLD FILTER Spread a thin layer o...

Page 53: ...tity Torque Notes 1 Neutral sensor 1 10 Nm 7 38 lb ft 2 Plate fixing screw Torx M5x16 1 4 Nm 2 95 lb ft Loct 243 3 Bearing block washers fixing screw TSEI 1 10 Nm 7 38 lb ft Loct 243 4 Breather cap 1 20 Nm 14 75 lb ft V7 II ABS Maintenance MAIN 53 ...

Page 54: ...N OUT MORE EASILY AND COMPLETELY Place a container with suitable capaci ty under the drainage plug 2 Unscrew and remove the drainage plug 2 Unscrew and remove the filler plug 1 Drain the oil into the container allow several minutes for oil to drain out com pletely Check and if necessary replace the sealing washers of drainage plug 2 Remove any metal scrap attached to the drainage plug 2 magnet Rem...

Page 55: ...le Unhook the connector from the air box cover Remove the air box cover fixing screw Remove the air box cover Extract the air filter Throttle body removal Remove the clip clamp fixing the sleeve to the filter box CAUTION DURING REFITTING REPLACE THE CLIP CLAMP Loosen the clamps that secure the sleeve to the intake manifolds V7 II ABS Maintenance MAIN 55 ...

Page 56: ... Remove the sleeve Remove the battery Remove the MIU G3 control unit con nector support bracket fixing screw Disconnect the MIU G3 control unit connector Maintenance V7 II ABS MAIN 56 ...

Page 57: ...es the throttle body to the filter box Extract the throttle body laterally Remove the throttle body guard Loosen the gas cables fixing nuts on the throttle body and unhook them Remove the throttle body V7 II ABS Maintenance MAIN 57 ...

Page 58: ...s to frame M8x14 2 25 Nm 18 44 lb ft 2 Cradle front fixing screw M10x30 4 50 Nm 36 88 lb ft 3 Screw fastening gearbox to frame M10x55 2 50 Nm 36 88 lb ft 4 Pin fixing engine gearbox to chassis M10 1 50 Nm 36 88 lb ft 5 Battery supporting plate fixing screw M8x16 4 25 Nm 18 44 lb ft Maintenance V7 II ABS MAIN 58 ...

Page 59: ...m 18 44 lb ft Loctite 243 FILTER BOX pos Description Type Quantity Torque Notes 1 Air filter box fastening screw SWP 5x20 11 3 Nm 2 21 lb ft 2 Air filter box cover fastening screw SWP 5x14 4 3 Nm 2 21 lb ft Air filter housing removal Remove the saddle and the side fair ings Remove the battery Remove the rear wheel Remove the splash guard Remove the fuse box support fixing screws 1 V7 II ABS Mainte...

Page 60: ...he side enough to allow removal of the fixing screws 3 on the right side of the filter box sup port Disconnect the neutral switch connec tor Lift the air filter box enough to allow the support plate to be removed sliding out neutral switch cabling Unscrew the clamp that fastens the throttle body to the air filter box Maintenance V7 II ABS MAIN 60 ...

Page 61: ...connect the blow by pipe Remove the air box cover Remove sliding the complete filter box out toward the rear Air filter housing installation Insert the filter box from the rear V7 II ABS Maintenance MAIN 61 ...

Page 62: ...AR CARE THAT THE CLAMP IS POSI TIONED CORRECTLY INCORRECT POSITIONING WILL CAUSE VEHICLE MALFUNCTIONS Install the air box cover Connect the blow by and breather tubes Position the air filter box support tak ing car to pass the neutral switch ca bling through the hole Maintenance V7 II ABS MAIN 62 ...

Page 63: ...crews 2 on the left side of the filter box sup port Correctly position the air filter box on the support Fix the screws 1 of the fuse box sup port Checking the valve clearance If the timing system is very noisy check the clearance between the valves and the rocking levers NOTE ADJUST WITH COLD ENGINE WITH PISTON AT TOP DEAD CENTRE TDC IN COMPRESSION STROKE VALVES CLOSED V7 II ABS Maintenance MAIN ...

Page 64: ... Remove the left spark plug cover Disconnect the spark plug tube Remove the spark plug Remove the six head cover fixing screws and collect the washers Maintenance V7 II ABS MAIN 64 ...

Page 65: ...trol clearance between rockers and valve Inlet valve 0 15 mm 0 0059 in Exhaust valve 0 20 mm 0 0079 in The measurement must be taken using a special thickness gauge CAUTION IF CLEARANCE IS LARGER THAN RECOMMENDED THE TAPPETS WILL BE NOISY OTHERWISE THE VALVES DO NOT CLOSE CORRECTLY WHICH CAN LEAD TO PROB LEMS SUCH AS PRESSURE DROP ENGINE OVERHEAT VALVE BURN OUT ETC V7 II ABS Maintenance MAIN 65 ...

Page 66: ...Type Quantity Torque Notes 1 Brake pump U Bolt fixing screw M6 2 10 Nm 7 38 lb ft 2 Front brake calliper fixing screw M10x30 2 50 Nm 36 88 lb ft 3 Fixing screw for brake fluid pipe on pump and calliper 2 25 Nm 18 44 lb ft Maintenance V7 II ABS MAIN 66 ...

Page 67: ...IN 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 Top up Front brake Unscrew the two screws 1 of the brake fluid reservoir 2 using a Phillips screwdriver Lift and remove the cover 3 and screws 1 as well Remove the gasket 4 Rear brake Unscrew and remove ...

Page 68: ... 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 DO NOT EXCEED THE MAX LEVEL MARK WHEN BRAKE PADS ARE WORN AS YOU RISK SPILLING FLUID WHEN CHANGING THE BRAKE PADS CHECK BRAKING EFFICIENCY IN CASE OF EXCESSIVE TRAVEL OF THE BRAKE LEVER OR POOR...

Page 69: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 70: ...1 Speed sensor fastening screw M6 1 10 Nm 7 38 lb ft 2 Coil retainer nut M6 2 2 10 Nm 7 38 lb ft Voltage regulator fixing screw M6 2 10 Nm 7 38 lb ft Control unit cable grommet fixing M4 1 4 Nm 2 95 lb ft Thread form ing screws Electrical system V7 II ABS ELE SYS 70 ...

Page 71: ...02 pos Description Type Quantity Torque Notes 1 Fuse box bracket fixing screw M5x12 2 4 Nm 2 95 lb ft 2 Battery holder bracket fastening screw M6 2 Manual Components arrangement key V7 II ABS Electrical system ELE SYS 71 ...

Page 72: ...on of the cable harnesses how they are fixed to the motorcycle and potential problems are defined on the following sections in order to reach the objectives of vehicle reliability Materials used and corresponding quantities The electrical system consists of the following cable harnesses and parts 1 Main Cable Harness 1 Ground cable Negative Engine 1 Left H V Cable 1 Left H V Cable Sheath Grey 1 Ri...

Page 73: ...herefore proper vehicle operation Carry out the checks listed below 1 Check control unit connection and correct insertion of the relative rubber plug 2 Check the correct fastening of metallic bracket screw on the throttle body 3 Check the right and left injectors connection 4 Check the cylinder head temperature sensor connection Blue connector 5 Check correct insertion of H V Cables with Coils 6 C...

Page 74: ...th the CAI plug caps 23 Check the stand switch cable ties on the frame under the vehicle 24 Check that the key switch cable has no voltage 25 Check the speed sensors connections 26 Check the correct ABS connector connection THE ENCIRCLED CONNECTORS ARE CONSIDERED CRITICAL IN COMPARISON WITH ANY OTHER BECAUSE THE VEHICLE WILL STOP OR PRESENT A MALFUNC TION IF THEY ARE ACCIDENTALLY DISCONNECTED Undo...

Page 75: ...s the ambient temperature sensor to the front headlamp support plate 5 GPS wiring connector 6 Front headlamp connector 7 Clamp that secures the GPS predisposition to clutch cable 8 ABS Warning Light 9 MGCT warning light The wiring harness of the warning lights must pass in the points indicated in the figure V7 II ABS Electrical system ELE SYS 75 ...

Page 76: ...A1 1 Main wiring harness 2 Clamp that secures the main cabling to the headlamp support plate 3 Ambient temperature sensor 4 Clamp that secures the ambient temperature sensor to the front headlamp support plate 5 GPS wiring connector Electrical system V7 II ABS ELE SYS 76 ...

Page 77: ...or 4 Left turn indicator connector 5 Flywheel connector If deemed necessary the voltage reg ulator connector 1 and the flywheel 5 can be tightened with a clamp in or der to avoid them disconnecting 6 Clamp 7 Flywheel cable harness V7 II ABS Electrical system ELE SYS 77 ...

Page 78: ...ors once connected are positioned behind the steering tube TABLE D 1 Main cable harness 2 Gas cables 3 Cable tie that secures the main cabling to the frame in correspondence to the grey taping The gas cables must pass under the main cabling Electrical system V7 II ABS ELE SYS 78 ...

Page 79: ... 5 Cable tie that secures the cabling in correspond ence to the grey tapings 6 Profile guards TABLE F Pass all the cabling as indicated and move all the connectors ensuring that they have been correctly connected behind the steering tube TABLE G 1 Front brake switch 2 Clamps 3 Cable guide V7 II ABS Electrical system ELE SYS 79 ...

Page 80: ...TABLE H 1 Clamp 2 Cable guide TABLE I 1 Cable grommet 2 Speed sensor Electrical system V7 II ABS ELE SYS 80 ...

Page 81: ...ons 2 Clamp Central part TABLE A 1 Oil pressure bulb 2 Engine head temperature sensor 3 Right injector 4 Rear stop switch 5 Gear in neutral switch 6 Left injector TABLE B 1 Rear stop switch 2 Clamps 3 Cable grommet V7 II ABS Electrical system ELE SYS 81 ...

Page 82: ...ABLE C 1 Side stand switch 2 Clamps TABLE D 1 Side stand cabling 2 Cable tie that secures the side switch cabling to the frame TABLE E 1 Side stand switch connector Electrical system V7 II ABS ELE SYS 82 ...

Page 83: ...TABLE G 1 Positive starter motor cable 2 Cable grommet Check that the hood which covers the starter motor positive is inserted well and that the nut is secured correctly to the prescribed torque TABLE H 1 Gear in neutral switch 2 Cable grommet V7 II ABS Electrical system ELE SYS 83 ...

Page 84: ...ie that secures the main cabling to the frame V7 SPECIAL V7 STONE V7 RACER TABLE M 1 Left lambda probe 2 Right Lambda probe Pay close attention that the right lamb da probe cabling passes through the cable grommet 3 TABLE N 1 Left lambda probe connector 2 Cable tie that secures the cabling of the left lambda probe V7 STORNELLO Electrical system V7 II ABS ELE SYS 84 ...

Page 85: ...or the fixing of the right lambda probe connector TABLE N 1 Left lambda probe connector 2 Cable grommet that secures the wiring harness of the left lambda probe TABLE O 1 Neutral switch connector 2 Right Lambda probe connector 3 Cable tie that joins the switch connectors and the right lambda probe 4 Right lambda probe cable harness 5 Clamp TABLE P 1 Battery positive V7 II ABS Electrical system ELE...

Page 86: ...k that the end of the engine ground leads is positioned as illustrated in the image and that there is perfect surface contact once the screw is tightened 3 Taillight connector 4 Speed sensor connector 5 Clamps TABLE Q 1 Taillight connector 2 Speed sensor connector Hide the taillight and speed sensor connectors between the filter box and mudguard Electrical system V7 II ABS ELE SYS 86 ...

Page 87: ...mp TABLE S 1 Control unit connector 2 Control unit fastening bracket TABLE T 1 Module with resistance Pull UP TABLE U 1 Left cylinder coil The grey taping marks the left cylinder coil connector V7 II ABS Electrical system ELE SYS 87 ...

Page 88: ...tion of correct connection of the high voltage cable on the coils TABLE W 1 High voltage cable covered by black sheath for right cylinder 2 High voltage cable covered by grey sheath for left cylinder Electrical system V7 II ABS ELE SYS 88 ...

Page 89: ...TABLE X 1 Pick Up connector TABLE Y 1 Left horn 2 Right horn Back side TABLE A 1 Rear speed sensor cabling 2 Cable grommets V7 II ABS Electrical system ELE SYS 89 ...

Page 90: ...General wiring diagram key 1 Multiple connectors 2 Air temperature sensor 3 ABS warning light 4 Instrument panel Electrical system V7 II ABS ELE SYS 90 ...

Page 91: ...attery 21 Pull Up resistance 22 Fuses 23 Flywheel 24 Regulator 25 Lambda 1 left exhaust 26 Lambda 2 right exhaust 27 Side stand switch 28 Injection load relay 29 Fuel reserve sensor 30 Fuel pump 31 Injector 1 left cylinder 32 Injector 2 right cylinder 33 Coil 2 right cylinder 34 Coil 1 left cylinder 35 Neutral sensor 36 Oil sensor 37 Pick UP 38 Engine head temperature sensor 39 MIU G3 control unit...

Page 92: ...ation Cable colour Ar orange Az sky 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 II ABS...

Page 93: ...e is foreseen Battery recharge circuit RECHARGING SYSTEM Slightly lift the fuel tank being careful not to pull the pipes with the relative hooks Remove the connectors from the com partment behind the steering column Disconnect the three way connector 1 white NOTE THE ENGINE SIDE IS IDENTIFIED WITH THE LETTER A Measurement of resistance with engine off For a correct detection of the alternator resi...

Page 94: ...s Example Resistance of stage 1 read on the display 0 67 Ohm Resistance of the wires read on the display 0 47 Ohm Effective resistance stage 1 0 67 0 47 0 20 Ohm RESISTANCE MEASURE Winding stage Ambient temperature ohm Afterwards heat stabilisation ohm Stage 1 0 18 0 23 0 20 0 25 Zero load voltage Electrical system V7 II ABS ELE SYS 94 ...

Page 95: ...of the short cir cuit current a connector must be pre pared that generates a downstream short circuit between the three alterna tor cables Start the engine and with an ammeter clamp measure each single cable If there is a significant difference be tween the measure of the single cables other than 10 A this means that the alternator is defective and must be re placed CAUTION WITH THE ENGINE HOT THE...

Page 96: ...RT CIR CUIT Start up system check pick up input about 100 A STARTER COMMAND Function Commands engine starting through the injection control unit Operation Operating principle The starter button the brake switches the No 6 starter command relay and the injection control unit between PIN 6 and 10 are involved Level in electrical circuit diagram Start up relay Location Under the fuel tank Pin out 1 c...

Page 97: ... in the cabling or the relay if the short is in the relay NOTE IN CASE OF SHORT TO GROUND OPEN CIRCUIT NO ERROR WILL APPEAR SEE THE TROU BLESHOOTING CHAPTER THE ENGINE DOES NOT START 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 ...

Page 98: ...ment panel injection loads relay 15 A D Battery positive Instrument panel turn indicators bluedash 5 A E Battery positive MIU G3 ECU 5 A F Main fuse coil 1 and 2 injectors 1 and 2 lambda 1 and 2 30 A ABS FUSE DISTRIBUTION A ABS Control unit 20 A B Spare fuses 20 A Control unit Engine control unit Magneti Marelli MIU G3 Electrical system V7 II ABS ELE SYS 98 ...

Page 99: ...ack et CONNECTOR LOCATION if available behind the steering tube PINS PIN 1 Ground connection white PIN 2 Power supply voltage Output signal white brown NAVIGATOR Parameters Speed km h Vehicle speed ELECTRICAL ERRORS Speed sensor 5D90 electric malfunction Electrical fault in sensor or cable harness Troubleshooting Check the sensor connector and the ABS control unit connector If they are not OK rest...

Page 100: ...r or missing sensor tone wheel Or excessive distance between the sensor and the tone wheel or tone wheel with wrong number of teeth Troubleshooting Check that the speed sensor and the tone wheel are installed If they are not install them If they are check the speed sensor retainer 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...

Page 101: ...ult in sensor or cable harness 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 yellow brown cable between PIN 2 of the sensor on the cable harness side and PIN 11 of the ABS control unit connector If there is no continuity restore them If there is PIN 2 of the sensor on the cable harness ...

Page 102: ...ion after pressure reduction Faulty sensor or missing sensor tone wheel or excessive distance between the sensor and the tone wheel Troubleshooting Check that the speed sensor and the tone wheel are installed If they are not install them If they are check the speed sensor retainer 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...

Page 103: ...the signal Troubleshooting Disconnect the sensor connector Verify with the key ON the voltage between sensor PIN 1 3 If no voltage is detected check the continuity of the cabling between sensor PIN 1 and instrument panel connector PIN 13 Carry out the check procedure on instrument panel connector PIN 13 If the cabling is intact check for continuity with the sensor PIN 3 ground Check continuity of ...

Page 104: ...ng voltage value range minimum 0 5 V maximum 5 V Pin out 1 Engine speed sensor positive signal cable X2 2 Engine speed sensor negative signal cable X1 3 Engine speed sensor anti jamming cable blue green cable 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...

Page 105: ...bles Conduct tests from the sensor connector toward the sensor If the sensor value is incorrect restore the cabling replace the sensor If the value is correct conduct tests from PIN 20 and 29 of the Marelli control unit connector toward the cable harness Installation Place the sensor plus the corresponding spacers the air gap should be between 0 7 and 0 9 mm Engine temperature sensor Function indi...

Page 106: ...ct the connector of the control unit Measure the resistance value of the sensor at different temperatures between PIN 13 and 15 Disconnect the sensor connector Verify continuity of the cabling between the sensor connector and the control unit connector Control unit PIN 13 sensor PIN 2 and control unit PIN 15 sensor PIN 1 Restore the cabling if necessary If the cabling is intact but the sensor resi...

Page 107: ...eads and inter prets a voltage generated by the difference in oxy gen content between the exhaust fumes and the ambient It does not require an external supply source but in order to work properly it should reach a high operating temperature that is why there is a heating circuit inside Level in electrical circuit diagram Right Lamb da probe Location sensor right exhaust pipe connector near the thr...

Page 108: ...r PIN 2 corresponding to control unit connector PIN 12 if there is a short restore the cabling Open circuit Disconnect the control unit connector and the sensor connector Verify continuity of the cabling between the sensor connector and the control unit connector Control unit PIN 18 sensor PIN 1 and control unit PIN 12 sensor PIN 2 If necessary restore the cable harness If the cabling is intact an...

Page 109: ...Verify continuity of the cabling between the sensor connector and the injection relay sensor PIN 4 injection relay PIN 3 If necessary restore the cable harness If the cabling is intact and the error persists proceed with the following checks Short circuit to negative Disconnect the sensor connector Check the sensor connector PIN 3 ground insulation In the absence of insulation restore the cabling ...

Page 110: ...nector Verify that there is no short to battery positive on sensor connector PIN 1 corresponding to control unit connector PIN 11 if there is a short restore the cabling Verify that there is no short to battery positive on sensor connector PIN 2 corresponding to control unit connector PIN 12 if there is a short restore the cabling Open circuit Disconnect the control unit connector and the sensor c...

Page 111: ...rify that there is no short to battery positive on sensor connector PIN 3 corresponding to control unit connector PIN 31 if there is a short restore the cabling Open circuit Disconnect the control unit connector and the sensor connector Verify continuity of the cabling between the sensor connector and the control unit connector Control unit PIN 31 sensor PIN 3 If necessary restore the cable harnes...

Page 112: ...ite wire 2 Sensor signal green white wire 3 Heater ground white yellow 4 Heater power supply white ELECTRICAL ERRORS Check the air fuel ratio right Lambda probe P0130 short to positive open circuit short to negative or carburetion excessively lean signal not plausible for abnormal title correction or probe signal fault Error cause Short circuit to positive excessive voltage at PIN 18 or PIN 12 of ...

Page 113: ...nit Lambda probe heater P0135 shorted to positive shorted to negative open circuit Error cause Short circuit to positive excessive voltage at PIN 2 of the control unit connector Short circuit to negative lack of insulation from ground on the sensor connector PIN 4 Open circuit circuit interruption Troubleshooting Short circuit to positive Disconnect the control unit connector and the sensor connec...

Page 114: ... out 1 Sensor signal pink wire 2 Sensor signal green white wire 3 Heater ground violet white 4 Heater power red brown cable ELECTRICAL ERRORS Check the air fuel ratio right Lambda probe P0136 short to positive open circuit short to negative or carburetion excessively lean signal not plausible for abnormal title correction or probe signal fault Error cause Short circuit to positive excessive voltag...

Page 115: ...PIN 1 and PIN 2 are insulated from the ground and the error persists this means that there is a probable fault in the control unit Lambda probe heater P0141 shorted to positive shorted to negative open circuit Error cause Short circuit to positive excessive voltage at PIN 35 of the control unit connector Short circuit to negative lack of insulation from ground on the sensor connector PIN 4 Open ci...

Page 116: ... the petrol passage to open Level in electrical circuit diagram Coils and in jectors Right injector position on the intake manifold connector on injector Electrical characteristics 14 8 Ohm 5 at 20 C 68 F Pin out 1 Power 12V red brown cable 2 Ground grey red cable ELECTRICAL ERRORS Front injector P0201 shorted to positive shorted to negative open circuit Error cause Shorted to positive excessive v...

Page 117: ... injector and control unit connectors Verify continuity of the cabling between the control unit connector and the injector connector control unit PIN 32 injector PIN 2 In the absence of continuity restore the cabling LEFT INJECTOR Level in electrical circuit diagram Coils and in jectors Left injector position on the intake manifold connector on injector Electrical characteristics 14 8 Ohm 5 at 20 ...

Page 118: ...he check procedure of the injector and control unit connectors Verify continuity of the cabling between the control unit connector and the injector connector control unit PIN 34 injector PIN 2 In the absence of continuity restore the cabling 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 L...

Page 119: ...iagram turn the key to the ON position and activate the relay through the diagnostics instrument Verify the presence of voltage between relay connector PIN 1 and 2 toward the cabling If no voltage is read disconnect the control unit and verify insulation from battery positive of the relay PIN 1 or control unit PIN 22 Restore the cabling if necessary Shorted to negative Disconnect the injection rel...

Page 120: ...e cable 2 Power red brown cable ELECTRICAL ERRORS H V Coil P0351 shorted to positive open circuit or shorted to negative Error cause Shorted to positive excessive voltage at PIN 1 of the control unit connector Circuit open or shorted to negative interruption of the circuit or null voltage at PIN 1 of the control unit connector Troubleshooting Shorted to positive Disconnect the coil connector turn ...

Page 121: ...rify the coil connector PIN 1 ground insulation or control unit connector PIN 1 Restore the cabling if necessary RIGHT COIL Level in electrical circuit diagram Right coil and injector 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 Power red brown cable 2 ...

Page 122: ...am Coil PIN 1 relay PIN 3 If the above tests provided a positive result the coil should be replaced Shorted to negative Disconnect the control unit connector and the coil connector Verify the coil connector PIN 3 ground insulation or control unit connector PIN 8 Restore the cabling if necessary Engine oil pressure sensor Function Indicates the instrument panel if there is enough oil pressure 0 35 ...

Page 123: ... to check the pressure of the oil in the engine circuit 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 con nection the instrument panel turns on the neutral warning light Level in electrical circuit diagram Start up ena bling switches Location sensor rear upper s...

Page 124: ...e is continuity with the ground If there is continuity replace the sensor If there is no continuity this means that there is a short to ground of the green black cable which goes to PIN 3 of the control unit therefore restore the cabling If the error persists disconnect the terminals from control unit PIN 17 to instrument panel PIN 10 and verify continuity If there is no continuity restore the cab...

Page 125: ...violet cable between the sensor and control unit PIN 15 If absent restore the cable harness The vehicle starts even without pulling the clutch lever Troubleshooting Disconnect the terminals from the sensor and check that with the clutch released there is continuity between the two PINs If there is continuity replace the sensor If there is no continuity this means that the blue violet cable which g...

Page 126: ...y yellow cable between the sensor and PIN 19 of the control unit If absent restore the cable harness if present with the stand up check for continuity be tween the 2 PINs on the sensor If absent replace the sensor If present check for continuity to ground of the blue green cable on the cable harness side connector The vehicle with clutch operated and gear engaged starts but with the side stand ext...

Page 127: ...10 0 kOhm 5 Pin out 1 Voltage 5V pink cable 2 Ground blue cable 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 Restore if not OK If OK check continuity of pink cable between the...

Page 128: ...Check the ground insulation of the sensor connector pink cable If connected to ground restore the cabling If insulated from ground check correct resistance of the sensor if not OK replace the sensor if OK replace the instrument panel RUN STOP switch Function It tells the control unit if the rider wishes to enable engine start up or to keep the engine running Operation Operating principle If the dr...

Page 129: ... cable harness if it is OK set the key to KEY OFF and check the control unit connector if it is OK replace the Marelli control unit Engine does not shut off with switch in STOP disconnect the connector and verify with the switch set to STOP that there is continuity between the two grey light blue and red white cables sensor side If present replace the switch if absent this means that with the key ...

Page 130: ...t 19 Injection relay control Digital output 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 L...

Page 131: ...7 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 V7 II ABS Electrical system ELE SYS 131 ...

Page 132: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 133: ... screw M10x30 4 50 Nm 36 88 lb ft 3 Screw fastening gearbox to frame M10x55 2 50 Nm 36 88 lb ft 4 Pin fixing engine gearbox to chassis M10 1 50 Nm 36 88 lb ft 5 Battery supporting plate fixing screw M8x16 4 25 Nm 18 44 lb ft 6 Screw fixing license plate holder arc to chassis Stornello M8 2 2 25 Nm 18 44 lb ft V7 II ABS Engine from vehicle ENG VE 133 ...

Page 134: ... attached to a hoist Position a centre stand under the engine sump Position an engine support so as not to damage the rubber bellows of the drive shaft Removing the engine from the vehicle V7 SPECIAL V7 STONE V7 RACER Remove the two fixing screws of the collector cover and remove the latter NOTE REPEAT THE OPERATION FOR THE RIGHT COVER AS WELL Loosen the clamp between the ex haust end and the cata...

Page 135: ...EFT SILENC ER V7 STORNELLO Remove the fixing spring of the silenc er to the central manifold Unscrew and remove the fixing screw of the silencer at the support bracket and recover the nut and the washer Remove the muffler V7 II ABS Engine from vehicle ENG VE 135 ...

Page 136: ...the cen tral muffler to the front mufflers Undo and remove the screw fixing the central muffler to the support bracket Remove the central manifold Remove the starter motor power sup ply cable Engine from vehicle V7 II ABS ENG VE 136 ...

Page 137: ...or Remove the starter motor fixing screws Remove the starter motor Remove the lambda probe side stand and blow by recovery wiring retainer clamps Disconnect the connectors of the lambda probes V7 II ABS Engine from vehicle ENG VE 137 ...

Page 138: ...blow by recovery pipe after having removed the clip clamp V7 SPECIAL V7 STONE V7 RACER Remove the exhaust ring fixing nuts taking care to recover the washers Remove the spacers Engine from vehicle V7 II ABS ENG VE 138 ...

Page 139: ... nuts Loosen the clamps between the joint and the exhaust manifolds Remove the manifolds V7 STORNELLO Undo and remove the fixing nuts of the exhaust ring and recover the washers V7 II ABS Engine from vehicle ENG VE 139 ...

Page 140: ...ing nut and the spacers Remove the right front manifold Repeat the procedure for the left front manifold Remove the spark plug covers Disconnect the caps from the spark plugs Engine from vehicle V7 II ABS ENG VE 140 ...

Page 141: ...tubes from the big ends Remove the fixing screws of the injectors and disconnect them Disconnect the engine temperature sensor connector Loosen the retainer clamps of the sleeve from the intake pipe V7 II ABS Engine from vehicle ENG VE 141 ...

Page 142: ...le from the disengagement lever Remove the fixing screws of the right footrest support Remove the lower fixing pin of the cra dle making sure to collect the washer and the nut Remove the front fastening screws covers of the cradle Engine from vehicle V7 II ABS ENG VE 142 ...

Page 143: ...e cra dle making sure to recover the nuts and washers Remove the two rear screws that fix the cradle Disconnect the side stand switch con nector Remove the two screws with washer and relative nut V7 II ABS Engine from vehicle ENG VE 143 ...

Page 144: ...cable harness from the rear brake pipe Remove the screw and the relative nut fixing the left rear shock absorber Remove the screw fixing the right hand rear right shock absorber and pull it from the pin on the drive shaft Remove the central pin pulling it from the right side of the motorcycle Remove the two screws with washer and relative nut Engine from vehicle V7 II ABS ENG VE 144 ...

Page 145: ...the clamp disconnect the ABS sensor and rear stop Remove the fixing screw of the rear brake tank Remove the lower screws of the wheel housing Remove the clamp remove the wheel housing to allow sliding off the tank Remove the rear brake tank from the fork V7 II ABS Engine from vehicle ENG VE 145 ...

Page 146: ...INDEX OF TOPICS ENGINE ENG ...

Page 147: ...TO CONSULT THE CHAPTER ABOUT THE ENGINE AND ITS COMPONENTS PLEASE REFER TO THE APPROPRIATE MANUAL MSS Engine V750 IE My2012 V7 II ABS Engine ENG 147 ...

Page 148: ...INDEX OF TOPICS POWER SUPPLY P SUPP ...

Page 149: ...Circuit diagram key 1 Fuel tank 2 Throttle body 3 Fuel filter 4 Fuel delivery pipe 5 Fuel pump unit Injection V7 II ABS Power supply P SUPP 149 ...

Page 150: ...nition 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 Power supply V7 II ABS P SUPP 150 ...

Page 151: ...e several sensors engine revs engine temperature etc or values set by the control unit injection time ignition advance etc ENGINE PARAMETER READING SCREEN PAGE Navigator characteristic P A D S characteristic Description Value Engine rpm Engine rpm Rpm the minimum value is set by the control unit cannot be adjusted Entire throttle position Throttle angle Rpm the minimum value is set by the control ...

Page 152: ...tion time Injection time Left cylinder adaptive correc tion Lambda adaptive gain 1 Right cylinder adaptive correc tion Lambda adaptive gain 2 Atmospheric pressure Atmospheric pressure The value is estimated by the control unit Intake pressure Intake pressure Pressure detected in the intake duct Target idle rpm Idling target is a target value for the engine speed at the minimum set by the control u...

Page 153: ...tor characteristic P A D S characteristic Navigator Description Value P A D S Description Value Lean title left cylinder Lean title cylinder 1 Yes No Yes No Lean title right cylinder Lean title cylinder 2 Yes No Yes No Idle motor Idle motor Ready for start Open loop Closed loop OK start up O Loop ClosLoop Closed Left cylinder lambda control Lambda circuit 1 Open loop Closed loop Open Closed Diagno...

Page 154: ...rror Yes No Not detectable Yes No Fan relay Fan relay Not activated Activated OFF 2 active 1 active req 1 req 2 Engine mode Engine mode Undetermined Start up Start up stabilized Start up with decelera tion Start up with acceleration Idling compensated for start up En gine stable outside idling Engine idling Undeterm Start Stabil Start_dec Start_acc Min_Comp Stable Min Accel Decel Cut Off RCUT OFF ...

Page 155: ...uit to positive Short circuit to ground P0 13 0 Control of air fuel ratio Left lamb da probe Lambda probe signal Bank 1 short circuit to positive open circuit short circuit to negative or excessively lean carburation signal not plausible for title correction Short circuit to positive Open or short circuit to ground Signal not plausible P0 13 5 Left lambda probe heater Lambda heater circ Bank 1 sho...

Page 156: ...l circuit short circuit to positive short circuit or open circuit to negative Short circuit to positive Short circuit or open circuit to ground P0 50 5 Idle control Idle control Stepper motor short circuit to positive short circuit to negative open circuit overpressure Short circuit to positive Short circuit to ground Open circuit Overpressure above specifications P0 53 0 Light relay Headlamp rela...

Page 157: ...ion Value Throttle position self acquisi tion TPS reset Saved data file download Mem data download Down load Clearing Clearing memorized data Mem data download Down load Clearing Self adjustable parameters re set Self adjustable parameters re set V7 II ABS Power supply P SUPP 157 ...

Page 158: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 159: ... 1 Front wheel axle M18x1 5 1 80 Nm 59 00 lb ft 2 Front brake disc fixing screw M8x20 6 25 Nm 18 44 lb ft Loctite 243 3 ABS sensor fixing stud bolt M5 1 6 Nm 4 43 lb ft Loctite 243 4 Cable grommet retainer nut M6 1 10 Nm 7 38 lb ft V7 II ABS Suspensions SUSP 159 ...

Page 160: ...ner screw SWP 5 1 1 1 5 Nm 1 11 lb ft 2 Counterweight fixing screw M6 2 10 Nm 7 38 lb ft Loctite 243 3 Screw fastening the clutch control U bolt to the handlebar M6 2 10 Nm 7 38 lb ft 4 Mirror fixing M10 1 1 Manual Gas covers fastener screw M5 3 6 Nm 4 43 lb ft Suspensions V7 II ABS SUSP 160 ...

Page 161: ...ft 2 Semi handlebar fixing screw M6x25 4 10 Nm 7 38 lb ft 3 Counterweight fixing screw M6 2 10 Nm 7 38 lb ft Loctite 243 4 Screw fastening the clutch control U bolt to the semi handlebar M6 2 10 Nm 7 38 lb ft 5 Mirror fixing M10 1 1 Manual Gas covers fastener screw M5 3 6 Nm 4 43 lb ft V7 II ABS Suspensions SUSP 161 ...

Page 162: ...cap 1 1 50 Nm 36 88 lb ft 2 Calliper bracket fixing screws M6x30 2 10 Nm 7 38 lb ft 3 Screws fixing fork stanchions to upper and low er plate M10x40 2 2 50 Nm 36 88 lb ft 4 Headstock fixing ring nut M25x1 1 7 Nm 5 16 lb ft The fork must fall to one side by itself Suspensions V7 II ABS SUSP 162 ...

Page 163: ...18 44 lb ft 7 Screws fixing handlebar support U bolts to steering plate M10x60 2 50 Nm 36 88 lb ft Diagram key 1 Screw 2 Washer 3 Screw 4 Left sleeve 5 Upper bushing 6 Washer 7 Seal ring 8 Retainer ring 9 Dust gaiter 10 Stem 11 Lower bushing 12 Buffer 13 Counter spring 14 Complete pumping member 15 Spring 16 Pipe V7 II ABS Suspensions SUSP 163 ...

Page 164: ...ome plated cap Removing the fork legs The vehicle is equipped with a non adjustable fork The operations described below are valid for both stanchions CAUTION DURING THE OPERATIONS DESCRIBED BELOW THE STANCHIONS AND THEIR INTERNAL COMPONENTS SHOULD BE TIGHTENED ON A VICE MAKE SURE NOT TO DAMAGE THEM BY OVERTIGHTENING ALWAYS USE ALUMINIUM JAW CAPS Remove the front wheel Remove the front mudguard Sus...

Page 165: ...el forwards Undo the upper sealing screw Undo the lower sealing screw Slide off the stem downwards by turning it slightly first in one direction then to the opposite direction Draining oil To drain out the oil follow these steps Remove the stanchion V7 II ABS Suspensions SUSP 165 ...

Page 166: ...g them Unscrew the upper closing cap Pay attention to the possible thrust that the spring can cause to the loosened cap 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 Suspensions V7 II ABS SUSP 166 ...

Page 167: ... refit the stanchion otherwise replace the damaged elements NOTE FOR EASY DRAINAGE OF THE OIL INSIDE THE PISTON ROD PRESS THE STANCHION IN THE WHEEL HOLDER 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 remove it with the corresponding gasket Remove the dust scraper using a screwdriver as a lever C...

Page 168: ...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 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 ...

Page 169: ...sary 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 fork leg Insert the lower sliding bushing in its seat on the bearing tube Reassemble the bearing tube in the wheel holder fork leg V7 II ABS Suspensions SUSP 169 ...

Page 170: ... Screw the bottom screw and tighten it to the prescribed torque Insert the cap and the well lubricated sealing ring on the bearing tube Use a suitable inserting tool to push the sealing ring in the fork leg until it stops Fit the locking ring Suspensions V7 II ABS SUSP 170 ...

Page 171: ...ling oil Place the sleeve upright in a vice fitted with protection jaws Compress the sleeve in the stanchion Pour part of the fork oil into the sleeve Wait some minutes until the oil fills all the ducts Pour the remaining oil Pump out oil a few times 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 MU...

Page 172: ...g 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 Suspensions V7 II ABS SUSP 172 ...

Page 173: ...V7 II ABS Suspensions SUSP 173 ...

Page 174: ...on cap 1 1 50 Nm 36 88 lb ft 2 Calliper bracket fixing screws M6x30 2 10 Nm 7 38 lb ft 3 Screws fixing fork stanchions to upper and low er plate M10x40 2 2 50 Nm 36 88 lb ft 4 Headstock fixing ring nut M25x1 1 7 Nm 5 16 lb ft The fork must fall to one side by itself Suspensions V7 II ABS SUSP 174 ...

Page 175: ...teering plate M10x60 2 50 Nm 36 88 lb ft Adjusting play Undo and remove the screws and col lect the U bolt holding the handlebar Move the handlebar forward be care ful not to turn over the front brake fluid reservoir 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 V7 II ABS Suspensions SUSP ...

Page 176: ...rk 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 Suspensions V7 II ABS SUSP 176 ...

Page 177: ...Rear Shock absorbers REAR SUSPENSION pos Description Type Quantity Torque Notes 1 Upper screw fastening shock absorber to frame M6x35 2 10 Nm 7 38 lb ft Loctite 243 V7 II ABS Suspensions SUSP 177 ...

Page 178: ... Nm 25 81 lb ft 4 Screw fastening right shock absorber to stud bolt M6x18 1 10 Nm 7 38 lb ft Loctite 243 Removing Remove the screw fixing the right hand rear right shock absorber and pull it from the pin on the drive shaft Remove the screw and the relative nut fixing the left rear shock absorber Unscrew and remove the upper screws Remove the shock absorbers Suspensions V7 II ABS SUSP 178 ...

Page 179: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 180: ...ctite 243 3 ABS sensor fixing stud bolt M5 1 6 Nm 4 43 lb ft Loctite 243 4 Cable grommet retainer nut M6 1 10 Nm 7 38 lb ft Removal 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 Working on the right side of the motor cycle remove the cap from the pin Chassis V7 II ABS CHAS 180 ...

Page 181: ...AY ATTENTION TO THE CORRECT POSITIONING OF THE SPACER WHICH MUST BE INSER TED IN THE DUST SEAL UNTIL IT REACHES THE BEAR ING 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 ING V7 II ABS Chassis CHAS 181 ...

Page 182: ...umber ZGULWS00XEM200368 M16x1 5 1 120 Nm 88 51 lb ft 1 Rear wheel axle nut up to frame se rial number ZGULWS00XEM200369 M16x1 5 1 100 Nm 73 76 lb ft 2 Rear brake disc fixing screw M8x25 6 25 Nm 18 44 lb ft Loctite 243 3 ABS sensor support fixing screw M6 2 10 Nm 7 38 lb ft 4 ABS sensor fixing screw M5 1 6 Nm 4 43 lb ft Loctite 243 Rimozione Remove the complete rear brake calliper support Chassis V...

Page 183: ...ght shock absorber and pull it from the pin on the drive shaft Remove the screw and the relative nut fixing the left rear shock absorber Unscrew and remove the nut and col lect the washer Loosen the wheel pin locking screw V7 II ABS Chassis CHAS 183 ...

Page 184: ...r holder Remove the wheel pin and collect the spacer Remove the complete rear brake cal liper support Remove the rear wheel PLACE A SUPPORT UNDER THE SWINGARM TO AVOID THAT THE PROTECTION CASING OF THE CARDAN COULD BE DAMAGED Chassis V7 II ABS CHAS 184 ...

Page 185: ...des Spoke tension adjustment 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 IT IS IMPORTANT TO LOCK THE ROTATION OF ALL NIPPLES LOOSENING THE NIPPLE MODIFIES THE TENSION OF THE WHEEL SPOKES COMPROMISING THE SAFETY OF THE WHEEL RIMS AND THE STABILITY OF THE VEHICLE R...

Page 186: ...O 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 IT IS IMPORTANT TO LOCK THE ROTATION OF ALL NIPPLES LOOSENING THE NIPPLE MODIFIES THE TENSION OF THE WHEEL SPOKES COMPROMISING THE SAFETY OF THE WHEEL RIMS AND THE STABILITY OF THE VEHICLE Swinging arm REAR TRANSMISSION SWINGARM...

Page 187: ...Quantity Torque Notes 1 Rear wheel axle nut up to frame se rial number ZGULWS00XEM200368 M16x1 5 1 120 Nm 88 51 lb ft 1 Rear wheel axle nut up to frame se rial number ZGULWS00XEM200369 M16x1 5 1 100 Nm 73 76 lb ft 2 Rear brake disc fixing screw M8x25 6 25 Nm 18 44 lb ft Loctite 243 3 ABS sensor support fixing screw M6 2 10 Nm 7 38 lb ft 4 ABS sensor fixing screw M5 1 6 Nm 4 43 lb ft Loctite 243 Re...

Page 188: ...R V7 STORNELLO Remove the fixing nut of the cable grommet plate and disconnect it from the swingarm Remove the ABS sensor and the brake calliper Unscrew and remove the fixing screw of the calliper holder Chassis V7 II ABS CHAS 188 ...

Page 189: ...he left rear shock absorber Remove the screw fixing the right hand rear right shock absorber and pull it from the pin on the drive shaft Unscrew and remove the nut and col lect the washer Loosen the wheel pin locking screw V7 II ABS Chassis CHAS 189 ...

Page 190: ...llect the spacer Remove the rear brake calliper support Remove the rear wheel Cut the sealing clamp and lift the fold ing CAUTION PAY ATTENTION NOT TO CUT AND DAMAGE THE RUB BER FOLDING Unscrew the nuts Chassis V7 II ABS CHAS 190 ...

Page 191: ...med or damaged otherwise replace the joint 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 Check that the spring is not deformed otherwise replace...

Page 192: ...are not damaged Bevel gears Removing Undo the four nuts and collect the washers Slide off the gearcase together with the swingarm Slide off the sleeve from the pinion Slide off the spring Slide off the sealing ring Slide off the base Chassis V7 II ABS CHAS 192 ...

Page 193: ...ne Remove the housing of the swingarm Slide the complete case of the gear case Lock on the vice the sealing tool 19907100 of the bevel gear pair Insert the grooved shank of the pinion on the tool and unscrew the nut V7 II ABS Chassis CHAS 193 ...

Page 194: ...the pinion Slide off the shim adjustment washer Slide off the O ring Slide off the oil seal Slide of the tapered bearing from the case Slide off the O ring Slide off the spacer Slide off the two shim washers Chassis V7 II ABS CHAS 194 ...

Page 195: ...ollers are not damaged or worn otherwise replace them Check that the adjustment washers are not deformed or broken otherwise replace them Check that the sealing rings are not shattered spoiled or worn otherwise replace them Montaggio 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 V7 II ABS Chassis CH...

Page 196: ...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 Fit both shim washers on the pinion Fit the spacer on the pinion Fit the O ring Chassis V7 II ABS CHAS 196 ...

Page 197: ...on on the case us ing the suitable punch 19926100 Fit the oil seal Fit the O ring Fit the spacer Insert the grooved shank of the pinion on the tool 19907100 and tighten the nut Casing unit removal V7 II ABS Chassis CHAS 197 ...

Page 198: ...he 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 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 Chassis V7 II ABS CHAS 198 ...

Page 199: ... Undo the screws and collect the corre sponding safety plates Remove the conical crown Slide off the drilled bolt from the bear ing Remove the sealing ring V7 II ABS Chassis CHAS 199 ...

Page 200: ...aper or foamet steel foamet CAUTION PAY ATTENTION TO THE TYPE OF GASKETS PRESENT AS DURING INSTALLATION THE SAME SOLUTION MUST BE INSTALLED Remove the external ring of the needle bearing from the housing using the suitable extractor 19927500 Remove the sealing ring and the wash er Check Chassis V7 II ABS CHAS 200 ...

Page 201: ...lers otherwise replace it Check efficiency of every component and that the coupling surfaces of the housing and cover are not scored or 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 Che...

Page 202: ...r and their spacers and gaskets on the hous ing and provisionally tighten the screws On the crown holder drilled bolt fit a Universal extractor that with appro priate central spacers slightly presses the crown towards the brake disc side 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 Chas...

Page 203: ... 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 too far from the rotation axis of the crown approach the pinion by increas ing spacer thickness V7 II ABS Chassis CHAS 203 ...

Page 204: ...ch the crown by reducing spacer thickness Montaggio gruppo scatola 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 Chassis V7 II ABS CHAS 204 ...

Page 205: ...r using the suitable punch 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 V7 II ABS Chassis CHAS 205 ...

Page 206: ... Fit the crown Fit the plates and tighten the screws Insert the washer Insert the washer Chassis V7 II ABS CHAS 206 ...

Page 207: ...sc 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 V7 II ABS Chassis CHAS 207 ...

Page 208: ...he sleeve and base on the bevel pinion of the gearcase Correctly insert the stud bolts of the gearcase in the holes of the swingarm Screw the nuts with the washers with out locking them Exhaust Chassis V7 II ABS CHAS 208 ...

Page 209: ... 1 10 Nm 7 38 lb ft 3 Compensator fixing clamp screw to the silencer M6 2 10 Nm 7 38 lb ft 4 Lambda probe on compensator M18x1 5 1 38 Nm 28 03 lb ft 5 Nut fastening silencer to mounting plate M8 4 25 Nm 18 44 lb ft 6 Heat shield fixing screw M6x12 6 10 Nm 7 38 lb ft Loctite 270 7 Screw fixing silencer mounting plate to frame M8x40 2 25 Nm 18 44 lb ft V7 II ABS Chassis CHAS 209 ...

Page 210: ...rnello M6 1 10 Nm 7 38 lb ft 2 Lambda probe fastener M18x1 5 1 1 38 Nm 28 03 lb ft 3 Heat shield fixing screw M6 2 2 8 Nm 5 90 lb ft Loctite 270 4 Fixing silencer support to chassis screw nut M8 2 2 25 Nm 18 44 lb ft Exhaust pipe fixing nut to the engine M6 2 2 10 Nm 7 38 lb ft Chassis V7 II ABS CHAS 210 ...

Page 211: ...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 SHC screw 18 Silencer fixing bushing 19 Nut 20 Elastic plate 21 Lambda probe 22 Spacer 23 Bushing 24 Insulating washer 25 Silencer heat protection 26 U bolt 27 Flanged TBEI screw V7 II ABS Chassis CHAS 211 ...

Page 212: ...ht exhaust manifold 5 Fixing bracket 6 Bushing 7 Clip 8 Rubber ring 9 Silencer protection 10 Heat protection 11 Screw 12 Washer 13 Screw 14 Washer 15 Spring with rubber 16 Washer 17 Spacer 18 Spring 19 Screw 20 Support bracket 21 Heat protection Chassis V7 II ABS CHAS 212 ...

Page 213: ...ne has been switched 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 V7 SPECIAL V7 STONE V7 RACER Loosens the clamps between the ex haust pipes and catalytic converter Unscrew and remove the muffler fixing nut and collect the screw and the bush ing Remove the silencer V7 STORNELLO V7 II ABS Chass...

Page 214: ...at the support bracket and recover the nut and the washer Remove the muffler Lock the two fixing screws as indicated in the figure using an appropriate wrench Unscrew and remove the two nuts 1 Remove the silencer supporting brack et 2 Removing the exhaust manifold V7 SPECIAL V7 STONE V7 RACER Chassis V7 II ABS CHAS 214 ...

Page 215: ... Remove the exhaust ring fixing nuts taking care to recover the washers Remove the spacers Remove the ring nuts Disconnect the left lambda probe con nector V7 II ABS Chassis CHAS 215 ...

Page 216: ...isconnect the right Lambda probe connector and slide the cabling from the cable grommet Loosen the clamps between the joint and the exhaust manifolds Remove the manifolds V7 STORNELLO Remove the fixing springs of the cen tral muffler to the front mufflers Chassis V7 II ABS CHAS 216 ...

Page 217: ...e the central manifold Disconnect the connectors of the lamb da probes The procedure of the removal as shown in the following also applies for the removal of the left front manifold Undo and remove the fixing nuts of the exhaust ring and recover the washers V7 II ABS Chassis CHAS 217 ...

Page 218: ...ers Remove the right front manifold Removing the lambda sensor V7 SPECIAL V7 STONE V7 RACER Remove the starter motor Disconnect the left lambda probe con nector 1 Disconnect the right Lambda probe connector 2 Chassis V7 II ABS CHAS 218 ...

Page 219: ... Unscrew and remove the lambda probes 3 V7 STORNELLO Disconnect the connectors of the lamb da probes Unscrew and remove the two lambda probes V7 II ABS Chassis CHAS 219 ...

Page 220: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 221: ...ABS ABS SYSTEM pos Description Type Quantity Torque Notes 1 Screw fixing ABS control unit support to chassis M6 3 10 Nm 7 38 lb ft key V7 II ABS Braking system BRAK SYS 221 ...

Page 222: ...C1 Vehicle identification ground connection PIN 4 IGN Injection PIN 8 WL Alarm warning light PIN 11 R_SIGN Rear ABS sensor signal PIN 12 R_GND Rear ABS sensor ground connection PIN 13 F_GND Front ABS sensor ground connection PIN 14 F_SIG Front ABS sensor signal PIN 15 PCC2 Vehicle identification ground connection PIN 16 ISO_K K line diagnosis PIN 18 KL30 Power supply Braking system V7 II ABS BRAK ...

Page 223: ...pump 7 Rear brake reservoir 8 ABS control unit front pump pipe 9 ABS control unit front calliper pipe 10 ABS control unit rear calliper pipe 11 ABS control unit rear pump pipe 12 Washer 13 Oil pipe screw 14 Stop switch 15 Bushing 16 Rubber ring 17 Screw 18 Washer 19 ABS control unit support V7 II ABS Braking system BRAK SYS 223 ...

Page 224: ...20 Brake pipe mounting plate 21 Pipes fixing plate 22 Screw 23 Clamp 24 Screw 25 Nut 26 Ring 27 Brake pipe support 28 Clip Braking system V7 II ABS BRAK SYS 224 ...

Page 225: ...Operating diagram ABS functional diagram key 1 Front system circuit 2 Front brake pump 3 Front brake lever 4 Rear system circuit V7 II ABS Braking system BRAK SYS 225 ...

Page 226: ...of the wheels in order to assess potential wheel slippage When in standby the system does not intervene at all when the rider brakes the braking system is the same as the one without ABS Stages in ABS cycle the following operations refer to the front circuit but are also applicable to the rear one A Brake activation the rider starts braking as he would usually do B Pressure reduction it coincides ...

Page 227: ...1 signals this out and adjusts the pressure in the braking circuit accordingly NOTE WHEN THE ABS SYSTEM STARTS WORKING A VIBRATION IS FELT ON THE BRAKE LEVER THE WHEEL ANTILOCK BRAKING SYSTEM DOES NOT PREVENT FALLS WHILE ON A BEND AN EMERGENCY BRAKING WITH THE VEHICLE INCLINED HANDLE BAR TURNED ON UN EVEN OR SLIPPERY ROADS OR WITH POOR GRIP CREATES LACK OF STABILITY DIFFICULT TO HANDLE THEREFORE R...

Page 228: ...warning light turns on permanently The ABS system is deactivated The system operates perfectly just as any other braking system without ABS The diagnosis requires exceeding the 5 km h Each time the key is ON if at least one current or stored error of the ABS system is not detected the ABS warning light flashes When the 5 km h 3 11 mph are exceeded if errors are not detected the ABS warning light t...

Page 229: ...12V at PIN 18 C 12V at PIN 4 with key ON 4 ARE THERE ANY ERRORS YES go to point 5 NO go to 6 5 CHECK THE ERRORS TABLE 6 ABS WARNING LIGHT ACTIVATION IS IT ACTIVATED YES go to point 7 NO go to point 8 7 CONTACT TECHNICAL SERVICE 8 PERFORM THESE CHECKS A Cable continuity between PIN8 of the ABS control unit connector and the instrument panel warning light B Check connectors refer to the operations d...

Page 230: ...several sensors engine revs engine temperature etc or values set by the control unit injection time ignition advance etc PARAMETERS P A D S characteristic Value example Unit of measure ment Notes Front wheel speed km h Rear wheel speed km h Battery voltage V Front brake circuit pressure bar Quality test of the sensors When turning the wheel or acting on the brake a variation of parameters must be ...

Page 231: ...sive difference Rear wheel speed sensor electrical diagnosis C1031 Short circuit or open circuit to negative or short circuit to positive Rear wheel speed sensor functional diagnosis C1032 Signal not valid Front wheel speed sensor electrical diagnosis C1033 Short circuit or open circuit to negative or short circuit to positive Front wheel speed sensor functional diagnosis C1034 Signal not valid In...

Page 232: ...e injection control unit diagnostics button U2927 Connect to the injection control unit diagnostics Inside error C1331 Pressure sensor failure Inside error C1332 Pressure sensor failure Offset Inside error C1333 Pressure sensor failure Power supply PADS report mode In the following are described the procedure to be performed through the diagnostic tool in order to generate an errors report When st...

Page 233: ... error where provided 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 V7 II ABS Braking system BRAK SYS 233 ...

Page 234: ...nel Modulator Before removing the modulator it is necessary to completely purge the braking system MODULATOR REMOVAL Remove the horn Disconnect the connector 1 With a felt tip pen mark a reference on the pipes and on the ABS control unit to avoid inverting them when refitting Remove the oil pipes in the order 3 4 6 5 Unscrew the nut of the oil pipe 3 and cover both the pipe and the hole on the mod...

Page 235: ...ulator that holds the support bracket of the ABS control unit Operating from the left side of the mo torcycle remove the ABS modulator To remove the ABS modulator from the support remove the three fixing screws V7 II ABS Braking system BRAK SYS 235 ...

Page 236: ...R BRAKE CALLIPER pos Description Type Quantity Torque Notes 1 Rear brake calliper fixing screw M8x30 2 25 Nm 18 44 lb ft Drilled screw for brake pipe on cal liper 1 25 Nm 18 44 lb ft key Braking system V7 II ABS BRAK SYS 236 ...

Page 237: ...calliper 7 Brake pads copy 8 Bleed valve and cover kit 9 Pins and spring kit Removal Obtain a special container and empty the system Remove the screw fixing the brake pipe to the clamp Remove the two calliper fixing screws Remove the calliper V7 II ABS Braking system BRAK SYS 237 ...

Page 238: ...e Quantity Torque Notes 1 Brake pump U Bolt fixing screw M6 2 10 Nm 7 38 lb ft 2 Front brake calliper fixing screw M10x30 2 50 Nm 36 88 lb ft 3 Fixing screw for brake fluid pipe on pump and calliper 2 25 Nm 18 44 lb ft key Braking system V7 II ABS BRAK SYS 238 ...

Page 239: ...ver 10 Bleed valve and cover kit 11 Pins and spring kit 12 Spring 13 Front left brake calliper 14 Washer 15 Screw 16 Screw 17 Brake pads copy Removal Obtain a special container and empty the system Remove the screw fixing the brake pipe to the clamp Remove the two calliper fixing screws V7 II ABS Braking system BRAK SYS 239 ...

Page 240: ...200368 M16x1 5 1 120 Nm 88 51 lb ft 1 Rear wheel axle nut up to frame se rial number ZGULWS00XEM200369 M16x1 5 1 100 Nm 73 76 lb ft 2 Rear brake disc fixing screw M8x25 6 25 Nm 18 44 lb ft Loctite 243 3 ABS sensor support fixing screw M6 2 10 Nm 7 38 lb ft 4 ABS sensor fixing screw M5 1 6 Nm 4 43 lb ft Loctite 243 Braking system V7 II ABS BRAK SYS 240 ...

Page 241: ...FITTING 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 Disc Inspection CAUTION THE BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE SPECI FICATIONS OF THE SYSTEM V7 II ABS Braking system BRAK SYS 241 ...

Page 242: ...e disc is less than the minimum value replace the disc Disc thickness minimum value 4 5 mm 0 18 in Front brake disc FRONT WHEEL pos Description Type Quantity Torque Notes 1 Front wheel axle M18x1 5 1 80 Nm 59 00 lb ft 2 Front brake disc fixing screw M8x20 6 25 Nm 18 44 lb ft Loctite 243 3 ABS sensor fixing stud bolt M5 1 6 Nm 4 43 lb ft Loctite 243 4 Cable grommet retainer nut M6 1 10 Nm 7 38 lb f...

Page 243: ...TING 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 Disc Inspection CAUTION THE FRONT BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE SPECIFICATIONS OF THE SYSTEM V7 II ABS Braking system BRAK SYS 243 ...

Page 244: ...ckness even in a single point 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 otherwise re place it Disc oscillation tolerance 0 15 mm 0 0059 in Front brake pads Removal Remove the Seeger locking the retain ing pins of the brake pads Remove the brak...

Page 245: ... Collect the protection plate Remove the brake pads Rear brake pads Removal Remove the rear brake calliper Remove the screws locking the brake pads V7 II ABS Braking system BRAK SYS 245 ...

Page 246: ...ING BRAKES AND RESTORING THE BRAKING SYSTEM TO THE REGULAR USE CON DITIONS THAT THE HYDRAULIC CIRCUIT BE AIR PURGED NOTE THE VEHICLE MUST BE ON LEVEL GROUND TO BE PURGED WHILE PURGING THE HYDRAUL IC SYSTEM FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID CHECK THAT DURING THE OPERATION THERE IS ALWAYS BRAKE FLUID IN THE RESER VOIR The bleeding procedure can be performed in a tradition...

Page 247: ...oil reservoir cap Refit the rubber protection cover Rear 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 CAUTION CONSIDERING THE DANGER FOR VEHICLE AND RIDER IT IS STRICTLY NECESSA...

Page 248: ... Operate the brake lever and then open the bleed valve on the calliper 1 4 of a turn to let the air out Close the bleed again before reaching the lever end of the stroke and repeat the operation until there is no air Screw the bleeding valve and remove the pipe Top up the reservoir until the correct brake fluid level is obtained Refit and lock the rear brake oil reservoir cap Refit the rubber prot...

Page 249: ...ew M6 2 10 Nm 7 38 lb ft 2 Front brake calliper fixing screw M10x30 2 50 Nm 36 88 lb ft 3 Fixing screw for brake fluid pipe on pump and calliper 2 25 Nm 18 44 lb ft Removal Remove the rear view mirror Drain off the front brake system Disconnect the brake switch connec tors V7 II ABS Braking system BRAK SYS 249 ...

Page 250: ...STEM WITH THE RELATIVE BLEEDING PROCEDURE TO AVOID AIR BUBBLES IN THE SYSTEM Rear brake pump REAR BRAKE LEVER pos Description Type Quantity Torque Notes 1 Nut fixing rear brake lever M8 1 20 Nm 14 75 lb ft 2 Rear brake fluid reservoir fixing screw M5x15 1 3 Nm 2 21 lb ft Braking system V7 II ABS BRAK SYS 250 ...

Page 251: ... 2 Rear brake lever fixing screw M6x20 1 10 Nm 7 38 lb ft Loctite 243 3 Screw fastening rider footrest mount ing to plate M8 1 25 Nm 18 44 lb ft Loctite 243 4 Rear brake pump fixing screw M6x25 2 8 Nm 5 90 lb ft Loctite 243 5 Rear brake fluid reservoir fixing screw M5x15 1 6 Nm 4 43 lb ft 6 Nut fastening rod terminal on brake lever M6 1 10 Nm 7 38 lb ft Rimozione Drain off the rear brake system Re...

Page 252: ...aft Remove the brake pipe by acting on the fitting and remove the complete pump CAUTION DURING REFITTING FILL UP THE BRAKE SYSTEM WITH THE RELATIVE BLEEDING PROCEDURE TO AVOID AIR BUBBLES IN THE SYSTEM Braking system V7 II ABS BRAK SYS 252 ...

Page 253: ...INDEX OF TOPICS BODYWORK BODYW ...

Page 254: ...screw M6x25 2 10 Nm 7 38 lb ft 2 Side fairing fixing screw M5x9 2 4 Nm 2 95 lb ft BODYWORK CENTRAL SECTION SADDLE pos Description Type Quantity Torque Notes 1 Saddle release block fixing screw M6x25 2 10 Nm 7 38 lb ft 2 Throttle body cover fastener screw M5x14 4 4 Nm 2 95 lb ft Bodywork V7 II ABS BODYW 254 ...

Page 255: ...block fixing screw Stornello M5x12 2 5 Nm 3 69 lb ft 2 Side fairing fixing screw M6 2 2 8 Nm 5 90 lb ft 3 Side fairing fixing screw M5 1 1 5 Nm 3 69 lb ft 4 Screw fixing oval plate to side fairing M6 2 2 5 Nm 3 69 lb ft 5 Throttle body cover fastener screw M6 1 1 4 Nm 2 95 lb ft Loctite 243 Throttle body cover support fastener screw M6 1 1 10 Nm 7 38 lb ft V7 II ABS Bodywork BODYW 255 ...

Page 256: ...ft 2 Rear turn indicator fixing screw M6 2 5 Nm 3 69 lb ft CARROZZERIA PARTE POSTERIORE PORTATARGA Pos Descrizione Tipo Quantità Coppia Note 1 Retroreflector support fixing screw to the license plate M5x10 2 4 Nm 2 95 lb ft 2 Retroreflector fixing nut retainer to the support M5 1 4 Nm 2 95 lb ft Bodywork V7 II ABS BODYW 256 ...

Page 257: ... screw Special Stone Racer M6 2 1 10 Nm 7 38 lb ft 1 Screw fixing rear mudguard bracket to chassis Stornello M6 2 10 Nm 7 38 lb ft 2 Rear mudguard side fixing screw Special Stone Racer M8x30 2 20 Nm 14 75 lb ft 2 Rear mudguard fixing screw Stornello M6 4 8 Nm 5 90 lb ft V7 II ABS Bodywork BODYW 257 ...

Page 258: ...te holder to mudguard reinforcement Special Stone Racer SWP M5x20 3 3 Nm 2 21 lb ft FUEL TANK pos Description Type Quantity Torque Notes 1 Rear tank fixing screw M8 1 25 Nm 18 44 lb ft 2 Screw fastening cap flange to tank M4 5 3 Nm 2 21 lb ft Bodywork V7 II ABS BODYW 258 ...

Page 259: ...ssembling the lock Remove the left side fairing Remove the fork spring Remove the cable support plate Extract the ignition switch assembly externally Taillight assy V7 STORNELLO V7 II ABS Bodywork BODYW 259 ...

Page 260: ...do and remove the two fixing screws 2 Remove the light unit complete from the support bracket Unscrew and remove the two screws 3 Remove the cover 4 Slide off the bulb holder 5 form its seat Disconnect the three connectors 6 Side body panels V7 SPECIAL V7 STONE Bodywork V7 II ABS BODYW 260 ...

Page 261: ...fairing V7 RACER Remove the side fairing fixing screw 1 Remove the side fairing To remove the left side fairing the sad dle opening cable 3 must be un hooked from the ignition switch assem bly 4 V7 STORNELLO Undo and remove the two number plate holder fixing screws 1 Remove the number plate holder 2 V7 II ABS Bodywork BODYW 261 ...

Page 262: ...hree washers 6 License plate holder V7 STORNELLO Remove the saddle Remove the silencer Remove the windscreen of the rear mud guard Remove the rear light unit Lock the two fixing screws as shown in the figure Unscrew and remove the two nuts 1 Remove the rear frame 2 Unscrew and remove the four screws 3 Bodywork V7 II ABS BODYW 262 ...

Page 263: ...e Remove the upper central screw 1 that secures the mudguard to the frame After unhooking the opening cable from the ignition switch assembly re move it from the mudguard Remove the front screws 2 that se cure the mudguard to the frame taking care to recover the nuts V7 II ABS Bodywork BODYW 263 ...

Page 264: ...m both sides taking care to recover the nuts Disconnect the taillight connector Remove the rear mudguard by sliding the light cabling through the wheel housing V7 STORNELLO Remove the saddle Lock the nut 1 with a suitable wrench Unscrew and remove the screw 2 Bodywork V7 II ABS BODYW 264 ...

Page 265: ...ndo and remove the fixing screw 6 Recover the washer 7 and the two spacers 8 and 9 Remove the rear mudguard 10 For the removal of the support bracket 12 of the rear mudguard undo and remove the two screws 11 Remove the supporting clamp 12 Then recover the washer 13 the spacer 14 and the rubber 15 V7 II ABS Bodywork BODYW 265 ...

Page 266: ...guard Remove the lower screws 1 Remove the upper screws 2 taking care to recover the nuts Remove the splash guard pulling it to the rear Fuel tank V7 SPECIAL V7 STONE V7 STORNELLO Bodywork V7 II ABS BODYW 266 ...

Page 267: ... order to be able to disconnect the fuel hose fitting avoiding damaging it CAUTION PAY PARTICULAR ATTENTION DURING THE LIFTING OP ERATION IN THAT THE FUEL HOSE FITTING CAN BE DAM AGED Disconnect the connector Remove the fuel breather pipe V7 II ABS Bodywork BODYW 267 ...

Page 268: ...the horns Unscrew and remove the rear screw Partially lift the fuel tank in order to be able to disconnect the fuel hose fitting avoiding damaging it CAUTION PAY PARTICULAR ATTENTION DURING THE LIFTING OP ERATION IN THAT THE FUEL HOSE FITTING CAN BE DAM AGED Bodywork V7 II ABS BODYW 268 ...

Page 269: ... Disconnect the connector Remove the fuel breather pipe Remove the fuel tank by sliding it off and back V7 II ABS Bodywork BODYW 269 ...

Page 270: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 271: ...ts 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 starter Engine stop via emergency stop switch and side stand Through the diagnosi...

Page 272: ...GETS IN CONTACT WITH YOUR EYES WASH WITH ABUNDANT WATER FOR FIFTEEN MINUTES AND CONSULT AN EYE SPECIALIST IMMEDIATELY THE BATTERY RELEASES EXPLOSIVE GASES KEEP IT AWAY FROM FLAMES SPARKS CIGARETTES OR ANY OTHER HEAT SOURCES ENSURE ADE QUATE VENTILATION WHEN SERVICING OR RECHARGING THE BATTERY KEEP OUT OF THE REACH OF CHILDREN BATTERY LIQUID IS CORROSIVE DO NOT POUR IT OR SPILL IT PARTICULARLY ON P...

Page 273: ...pection Hydraulic 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 RECOMME...

Page 274: ...5 Nm 18 44 lbf ft 3 Passenger footrest mounting bracket fixing screw M8x16 4 25 Nm 18 44 lbf ft Loctite 243 4 Countersunk head Allen screw M8 2 25 Nm 18 44 lbf ft WARNING OPERATIONS REQUIRED TO RENDER VEHICLE COMPLIANT WITH TWO SEATER TYPE AP PROVAL Remove the three fixing screws of the exhaust mounting plate Remove the mounting plate Pre delivery V7 II ABS PRE DE 274 ...

Page 275: ...ntersunk screw with hexag onal hole on C supporting the pedal and afterwards fit the washer Place C on the exhaust supporting plate pay attention that the holes to in sert the pedal are adequately oriented Hold the countersunk screw with hex agonal hole firmly in place and tighten the nut to 25 Nm 18 44 lbf ft Position the pedal on C and insert the fixing pin V7 II ABS Pre delivery PRE DE 275 ...

Page 276: ...mento maniglie passeggero Remove the two shock absorber fixing screws Turn the shock absorber as shown and fasten it at the bottom Fit the passenger handgrip and tighten the screw to the prescribed torque Tighten the passenger handgrip rear fastening screw NOTE REPEAT THE PROCEDURE TO MODIFY EVEN THE OTHER SIDE Pre delivery V7 II ABS PRE DE 276 ...

Page 277: ...lease block fixing screw M6x25 2 10 Nm 7 38 lb ft 2 Throttle body cover fastener screw M5x14 4 4 Nm 2 95 lb ft 3 Side fairing fixing screw M5x9 6 4 Nm 2 95 lb ft Sostituzione sella Insert the key in the lock and turn it clockwise Remove the single seat saddle V7 II ABS Pre delivery PRE DE 277 ...

Page 278: ... Place the two seat saddle Pre delivery V7 II ABS PRE DE 278 ...

Page 279: ...rake pads 244 245 Brake pump 249 250 Bulbs C Clutch 124 Coil 120 Connectors 129 D Diagnostics 229 Display E ECU 129 151 230 Electrical system 12 70 72 271 Engine oil 51 Engine temperature sensor 105 Exhaust 208 214 Exhaust manifold 214 F Filter box Fork 162 164 167 169 172 Front wheel 180 Fuel 118 266 Fuel pump 118 Fuses 98 G Gearbox oil 53 H Handlebar 160 I Identification 10 ...

Page 280: ...ressure sensor 122 R Rear wheel 182 Recommended products 42 Run Stop switch 128 S Saddle Scheduled maintenance 48 Shock absorbers 177 Side stand 125 Side stand sensor 125 Spark plugs Speed sensor 99 Stand 125 Start up 96 T Tank 266 Throttle body 55 Transmission 12 49 Tyres 14 U Use 229 W Warning lights Wiring diagram 90 ...

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