MOTO GUZZI V7 Stone Servise Manual
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MOTO GUZZI V7 Stone Servise Manual

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MANUALE STAZIONE DI SERVIZIO
B043094
V7 Stone - V7 Special - V7 Racer

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  • Page 1 MANUALE STAZIONE DI SERVIZIO B043094 V7 Stone - V7 Special - V7 Racer...
  • Page 2 The reliability of the vehicle also depends on its mechanical conditions. Checking the vehicle before riding it, its regular maintenance and the use of original Moto Guzzi spare parts only are essential factors! For information on the nearest Official Dealer and/or Service Centre consult our website: www.motoguzzi.com...
  • Page 3 Le principali modifiche tecniche e modifiche alle procedure per le riparazioni del veicolo vengono comunicate a tutti i Punti Vendita Moto Guzzi e alle Filiali nel Mondo. Tali modifiche verranno apportate, nelle edizioni successive di questo manuale. Nel caso di necessità o dubbi sulle procedure di riparazione e di controllo, interpellare il REPARTO ASSISTENZA Moto Guzzi, il quale sarà...
  • Page 4 Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee...
  • Page 5 INDEX OF TOPICS CHAR HARACTERISTICS S-TOOLS PECIAL TOOLS MAIN AINTENANCE ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE P SUPP OWER SUPPLY SUSP USPENSIONS CHAS HASSIS BODYW ODYWORK PRE DE DELIVERY...
  • Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 7: Safety Rules

    V7 Stone - V7 Special - V7 Racer Characteristics Rules Safety rules Carbon monoxide If you need to keep the engine running while working on the vehicle, please ensure that you do so in an open or very well ventilated area. Never let the engine run in an enclosed area. If you do work in an enclosed area, make sure to use a fume extraction system.
  • Page 8 V7 Stone - V7 Special - V7 Racer Characteristics BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAINTED SURFACES. WHEN SERVICING THE BRAKING OR THE CLUTCH SYSTEM PROTECT THESE COMPONENTS WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THESE SYSTEMS.
  • Page 9 V7 Stone - V7 Special - V7 Racer Characteristics Keep mated parts together since they have "adjusted" to each other due to normal wear. • Some components must be used together or replaced altogether. • Keep away from heat sources.

  • Page 10: Vehicle Identification

    That is to permit the adequate adjustment of the pad friction material to the brake discs. AFTER THE SPECIFIED MILEAGE, TAKE THE VEHICLE TO AN OFFICIAL Moto Guzzi DEALER FOR THE CHECKS INDICATED IN THE "AFTER RUN-IN" TABLE IN THE SCHEDULED MAINTE- NANCE SECTION TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHI- CLE.
  • Page 11 ZGULWE0012MXXXXXX KEY: ZGU: WMI (World manufacturer identifier) code; LW: model; E00 (V7 Stone), G00 (V7 Special), H00 (V7 Rac- er): versions; 0: free digit 12: variable year of manufacture (12 - for 2012) M: production plant (M= Mandello del Lario);...
  • Page 12 V7 Stone - V7 Special - V7 Racer Characteristics Specification Desc./Quantity Engine capacity 744 cm³ (45.40 cu.in) Bore / stroke 80x74 mm (3.14x2.91 in) Compression ratio 10.4 : 1 Electric Electric starter Engine idle speed 1350 +/- 100 rpm Intake valve clearance 0.15 mm (0.0059 in)

  • Page 13: Warning Lights

    V7 Stone - V7 Special - V7 Racer Characteristics Specification Desc./Quantity Alternatively: CHAMPION RG6YC Spark plug electrode gap 0.6 - 0.7 mm (0.024 - 0.027 in) Resistance 5 kOhm BULBS Specification Desc./Quantity Low/high beam light (halogen) 12 V - 55 W / 60 W H4...

  • Page 14: Wheels And Tyres

    V7 Stone - V7 Special - V7 Racer Characteristics Brakes BRAKES Specification Desc./Quantity Front stainless steel floating disc, Ø 320 mm (12.59 in), callipers with 4 different and counteracting plungers Rear 260 mm (10.24 in) stainless steel disc, floating calliper with two 25.4 mm (1.00 in) diam.
  • Page 15 V7 Stone - V7 Special - V7 Racer Characteristics Front side RONT SUSPENSION TEERING pos. Description Type Quantity Torque Notes Stanchion cap 50 Nm (36.88 lbf ft) Screw fixing wheel axle to right fork leg M6x30 10 Nm (7.37 lbf ft)
  • Page 16 V7 Stone - V7 Special - V7 Racer Characteristics pos. Description Type Quantity Torque Notes Headstock bushing M23x1 50 Nm (36.88 lbf ft) NSTRUMENT PANEL pos. Description Type Quantity Torque Notes Screw fixing instrument panel to headlamp sup- M6x10 10 Nm (7.37 lbf ft)
  • Page 17 V7 Stone - V7 Special - V7 Racer Characteristics ANDLEBAR AND ONTROLS Pos. Description Type Quantity Torque Notes Switch fastener screw SWP 5 1.5 Nm (1.11 lb ft) Counterweight fixing screw 10 Nm (7.37 lb ft) Loctite 243 Screw fastening the clutch control U-bolt to M6x25 10 Nm (7.37 lb ft)
  • Page 18 V7 Stone - V7 Special - V7 Racer Characteristics RONT BRAKE SYSTEM pos. Description Type Quantity Torque Notes Screw fastening the brake pump U-bolt to the M6x25 10 Nm (7.37 lb ft) semi-handlebar Front brake calliper fixing screw M10x30 50 Nm (36.88 lb ft) Drilled screw for brake fluid pipe on pump and 25 Nm (18.44 lb ft)
  • Page 19 V7 Stone - V7 Special - V7 Racer Characteristics RONT LIGHTS pos. Description Type Quantity Torque Notes Headlamp fixing screw M8x30 15 Nm (11.06 lb ft) Front turn indicator fixing screw 5 Nm (3.69 lb ft) Horn fixing screw M6x16 10 Nm (7.37 lb ft)
  • Page 20 V7 Stone - V7 Special - V7 Racer Characteristics RONT WHEEL pos. Description Type Quantity Torque Notes Front wheel axle M18x1.5 80 Nm (59.00 lbf ft) Front brake disc fixing screw M8x20 25 Nm (18.44 lbf ft) Loctite 243 Central part...
  • Page 21 V7 Stone - V7 Special - V7 Racer Characteristics RAME pos. Description Type Quantity Torque Notes Screw fixing tank mounting rubber M8x14 25 Nm (18.44 lbf ft) blocks to frame Cradle front fixing screw M10x30 50 Nm (36.88 lbf ft)
  • Page 22 V7 Stone - V7 Special - V7 Racer Characteristics RIVER FOOTRESTS pos. Description Type Quantity Torque Notes Pedal rubber fastening screw M6x12 10 Nm (7.38 lb ft) Screw fastening rider footrest mounting to 25 Nm (18.44 lb ft) Loct. 243...
  • Page 23 V7 Stone - V7 Special - V7 Racer Characteristics pos. Description Type Quantity Torque Notes Preselector lever fixing screw M6x20 10 Nm (7.37 lb ft) Gearbox lever fixing screws M6x20 10 Nm (7.37 lb ft) Loctite 243 Gearbox control rod fixing nut M6x1 10 Nm (7.37 lb ft)
  • Page 24 V7 Stone - V7 Special - V7 Racer Characteristics IDE STAND pos. Description Type Quantity Torque Notes Side stand retainer pin M10x1.2 10 Nm (7.38 lb ft) Lock nut for stand bolt M10x1.2 30 Nm (22.13 lb ft) Switch fixing screw M5x16 6 Nm (4.42 lb ft)
  • Page 25 V7 Stone - V7 Special - V7 Racer Characteristics UEL TANK pos. Description Type Quantity Torque Notes Rear tank fixing screw M8x45 25 Nm (18.44 lb ft) Screw fastening cap flange to tank M5x12 4 Nm (2.95 lb ft) UEL SUPPLY SYSTEM pos.
  • Page 26 V7 Stone - V7 Special - V7 Racer Characteristics IGHTENING TORQUE ENTRAL PART ILTER BOX pos. Description Type Quantity Torque Notes Air filter box cover fastening screw SWP 5x14 3 Nm (2.21 lb ft) Air filter box fastening screw to frame SWP 5x20 3 Nm (2.21 lb ft)
  • Page 27 V7 Stone - V7 Special - V7 Racer Characteristics ODYWORK CENTRAL SECTION ADDLE pos. Description Type Quantity Torque Notes Saddle release block fixing screw M6x25 10 Nm (2.37 lb ft) Side fairing fixing screw M5x9 4 Nm (2.95 lb ft)
  • Page 28 V7 Stone - V7 Special - V7 Racer Characteristics OCK KIT pos. Description Type Quantity Torque Notes (Shear head) screw fixing ignition M8x15 At the point of failure lock Ignition lock fixing screw M8x16 25 Nm (18.44 lb ft) CHAR - 28...
  • Page 29 V7 Stone - V7 Special - V7 Racer Characteristics XHAUST SYSTEM Pos. Description Type Quantity Torque Notes Exhaust pipe fixing nut to the engine 10 Nm (7.37 lb ft) Exhaust pipe fixing clamp screw to 10 Nm (7.37 lb ft)
  • Page 30 V7 Stone - V7 Special - V7 Racer Characteristics (V7 RACER) EAR SUSPENSION pos. Description Type Quantity Torque Notes Upper screw fastening shock absorber to M6x35 10 Nm (7.37 lbf ft) Loctite 243 frame Lower pin fastening left shock absorber to M10x1.5...
  • Page 31 V7 Stone - V7 Special - V7 Racer Characteristics pos. Description Type Quantity Torque Notes Stud bolt fixing right shock absorber to rear M12x1.5 35 Nm (25.81 lbf ft) Screw fastening right shock absorber to stud M6x16 10 Nm (7.37 lbf ft)
  • Page 32 V7 Stone - V7 Special - V7 Racer Characteristics EAR WHEEL pos. Description Type Quantity Torque Notes Rear wheel axle nut M16x1.5 120 Nm (88.51 lb ft) Rear brake disc fixing screw M8x25 25 Nm (18.44 lb ft) Loctite 243 EAR BRAKE SYSTEM pos.
  • Page 33 V7 Stone - V7 Special - V7 Racer Characteristics pos. Description Type Quantity Torque Notes Drilled screw for brake pipe on cal- 25 Nm (18.44 lb ft) liper EAR LIGHTS pos. Description Type Quantity Torque Notes Screw fastening taillight support to M5x14 4 Nm (2.95 lbf ft)
  • Page 34 V7 Stone - V7 Special - V7 Racer Characteristics EAR SECTION BODYWORK ICENSE PLATE MOUNTING pos. Description Type Quantity Torque Notes Screw fastening retroreflector mounting to license M5x10 4 Nm (2.95 lbf ft) plate mounting Nut fixing retroreflector to mounting 4 Nm (2.95 lbf ft)
  • Page 35 V7 Stone - V7 Special - V7 Racer Characteristics EAR MUDGUARD pos. Description Type Quantity Torque Notes Rear mudguard front and central fixing screw 10 Nm (7.37 lb ft) Rear mudguard side fixing screw M8x30 25 Nm (18.44 lb ft) Screw fixing license plate holder to mudguard 3 Nm (2.21 lb ft)
  • Page 36 V7 Stone - V7 Special - V7 Racer Characteristics LECTRICAL SYSTEM pos. Description Type Quantity Torque Notes 1 - Coil fixing nut 10 Nm (7.37 lb ft) 2 - Timing sensor fastener screw .. Nm (... lb ft) Recommended products chart...
  • Page 37 INDEX OF TOPICS S-TOOLS PECIAL TOOLS...

  • Page 38: Special Tools

    V7 Stone - V7 Special - V7 Racer Special tools SPECIAL TOOLS Stores code Description 19.92.61.00 Punch for seal ring of bevel gear set pin- 19.92.88.00 Bevel gear set alignment pre-fitting tool 19.92.60.00 Punch for gearcase sealing ring 19.90.70.00 Extractor for internal ring on drilled bolt 19.92.75.00...
  • Page 39 V7 Stone - V7 Special - V7 Racer Special tools Stores code Description 19.92.64.00 Punch for external ring of tapered bearing on bevel gear set pinion holding body 19.92.65.00 Punch for external ring of gearcase bear- 19.92.76.00 Extractor for swinging arm holder bearing...
  • Page 40 INDEX OF TOPICS MAIN AINTENANCE...

  • Page 41: Maintenance Chart

    V7 Stone - V7 Special - V7 Racer Maintenance Maintenance chart NOTE CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VE- HICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS, OFF ROAD OR FOR TRACK USE. NOTE THE TIMES LISTED ON THE SCHEDULED MAINTENANCE TABLE INCLUDE TIME DEDICATED TO MANAGEMENT ACTIVITIES.

  • Page 42: Transmission Fluid

    V7 Stone - V7 Special - V7 Racer Maintenance Transmission fluid Check • Keep the vehicle upright with both wheels on the ground. • Unscrew and remove the cap/dipstick (1). • The level is correct if the oil is close to the hole of the cap/dipstick (1).

  • Page 43: Engine Oil

    V7 Stone - V7 Special - V7 Racer Maintenance Screw and tighten the caps (1 - 2). • Engine oil Check CAUTION ENGINE MUST BE WARM TO CHECK ENGINE OIL LEVEL NOTE DO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT STANDSTILL TO WARM UP THE ENGINE AND REACH THE OPERATING TEMPERATURE OF ENGINE OIL.
  • Page 44 V7 Stone - V7 Special - V7 Racer Maintenance CAUTION DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCE TO THE OIL. WHEN USING A FUNNEL OR ANY OTHER ELE- MENT, MAKE SURE IT IS PERFECTLY CLEAN. Replacement Place a container with + 2000 cm³ (122 •...

  • Page 45: Engine Oil Filter

    V7 Stone - V7 Special - V7 Racer Maintenance Engine oil filter Loosen the screw (3) and remove the • cover (4). Remove the engine oil filter (5). • NOTE NEVER REUSE AN OLD FILTER. Spread a thin layer of oil on the sealing ring (6) of the new engine oil filter.

  • Page 46: Throttle Body Removal

    V7 Stone - V7 Special - V7 Racer Maintenance Throttle body removal Loosen the clamps that secure the • sleeve to the intake manifolds Remove the sleeve • Remove the battery • Remove the MIU G3 control unit con- •...
  • Page 47 V7 Stone - V7 Special - V7 Racer Maintenance Disconnect the MIU G3 control unit • connector Unscrew the clamp that secures the • throttle body to the filter box Extract the throttle body laterally • Remove the throttle body guard •...

  • Page 48: Throttle Body Installation

    V7 Stone - V7 Special - V7 Racer Maintenance Remove the throttle body • Throttle body installation Connect the gas cables on the throttle • body Correctly position the guides and tight- • en the nuts, checking correct operation of the throttle grip Install the throttle body guard •...
  • Page 49 V7 Stone - V7 Special - V7 Racer Maintenance Insert the throttle body in the sleeve • and tighten the clamp to secure it CAUTION TAKE PARTICULAR CARE THAT THE CLAMP IS POSI- TIONED CORRECTLY. INCORRECT POSITIONING WILL CAUSE VEHICLE MALFUNCTIONS Connect the MIU G3 control unit con- •...
  • Page 50 V7 Stone - V7 Special - V7 Racer Maintenance Tighten the clamps, checking correct • positioning Air filter housing RAME pos. Description Type Quantity Torque Notes Screw fixing tank mounting rubber M8x14 25 Nm (18.44 lbf ft) blocks to frame...
  • Page 51 V7 Stone - V7 Special - V7 Racer Maintenance pos. Description Type Quantity Torque Notes Screw fastening gearbox to frame M10x55 50 Nm (36.88 lbf ft) Pin fixing engine/gearbox to chassis M10x205 50 Nm (36.88 lbf ft) Screw fixing exhaust silencer mount- M8x16 25 Nm (18.44 lbf ft)
  • Page 52 V7 Stone - V7 Special - V7 Racer Maintenance Move the filter box to the side enough • to allow removal of the fixing screws (2) on the left side of the filter box support. See also Side body panels...
  • Page 53 V7 Stone - V7 Special - V7 Racer Maintenance Unscrew the clamp that fastens the • throttle body to the air filter box Disconnect the blow-by and breather • tubes Remove the air-box cover • Remove sliding the complete filter box •...
  • Page 54 V7 Stone - V7 Special - V7 Racer Maintenance Air filter housing installation Insert the filter box from the rear • Insert the throttle body in the sleeve • and tighten the clamp to secure it CAUTION TAKE PARTICULAR CARE THAT THE CLAMP IS POSI- TIONED CORRECTLY.
  • Page 55 V7 Stone - V7 Special - V7 Racer Maintenance Position the air filter box support, tak- • ing car to pass the neutral switch ca- bling through the hole Move the filter box to the side enough • to allow tightening of the fixing screws (3) on the right side of the filter box support.

  • Page 56: Braking System

    V7 Stone - V7 Special - V7 Racer Maintenance Braking system RONT BRAKE SYSTEM pos. Description Type Quantity Torque Notes Screw fastening the brake pump U-bolt to the 10 Nm (7.37 lbf ft) Tighten using a 1-2-1 se- semi-handlebar quence...
  • Page 57 V7 Stone - V7 Special - V7 Racer Maintenance EAR BRAKE SYSTEM pos. Description Type Quantity Torque Notes Rear brake calliper fixing screw M8x30 25 Nm (18.44 lb ft) Drilled screw for brake pipe on cal- 25 Nm (18.44 lb ft)
  • Page 58 CHECK BRAKING EFFICIENCY. IN CASE OF EXCESSIVE TRAVEL OF THE BRAKE LEVER OR POOR PERFORM- ANCE OF THE BRAKING SYSTEM, TAKE YOUR VEHICLE TO AN Official Moto Guzzi Dealer, AS IT MAY BE NECES- SARY TO PURGE THE AIR IN THE SYSTEM. MAIN - 58...
  • Page 59 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 60 V7 Stone - V7 Special - V7 Racer Electrical system LECTRICAL SYSTEM pos. Description Type Quantity Torque Notes Speed sensor fastening screw 10 Nm (7.37 lb ft) Fuse box bracket fixing screw M5x12 4 Nm (2.95 lb ft) Battery holder bracket fastening screw...
  • Page 61 V7 Stone - V7 Special - V7 Racer Electrical system pos. Description Type Quantity Torque Notes 2 - Timing sensor fastener screw .. Nm (... lb ft) Components arrangement key: 1. Instrument panel 2. Coil ELE SYS - 61...
  • Page 62 V7 Stone - V7 Special - V7 Racer Electrical system 3. Fuel pump 4. Injector 5. Taillight 6. MIU G3 Control Unit 7. Speed sensor 8. Starter motor 9. Engine speed sensor 10.Fuses 11.Battery 12.Head temperature sensor 13.Instrument panel air sensor 14.Headlamp...
  • Page 63 V7 Stone - V7 Special - V7 Racer Electrical system 10 Medium black clamps 190x4.5 • 5 Small black 160x2.5 clamps • 1 Cable guides • 3 Cable grommet (there are various types of cable grommets) • 2 Profile guards (140mm long) •...
  • Page 64 V7 Stone - V7 Special - V7 Racer Electrical system 16.Check the presence of the Pull Up module and the presence of the black hose under the trans- parent one. 17.Check the Pick Up connection. 18.Check correct insertion of the starter motor hood 19.Check the presence of the Red protective hood on the battery Positive.
  • Page 65 V7 Stone - V7 Special - V7 Racer Electrical system TABLE A1 1. Main cable 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.
  • Page 66 V7 Stone - V7 Special - V7 Racer Electrical system 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 •...
  • Page 67 V7 Stone - V7 Special - V7 Racer Electrical system TABLE G 1. Front brake switch 2. Clamps 3. Cable guide TABLE H 1. Clamp 2. Cable guide Central part CAUTION ONCE THE ELECTRICAL SYSTEM IS REFITTED, THE CONNECTORS RECONNECTED AND CLAMPS AND RETAINERS RESTORED, CARRY OUT THE CHECKS INDICATED UNDER "SPE-...
  • Page 68 V7 Stone - V7 Special - V7 Racer Electrical system 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.
  • Page 69 V7 Stone - V7 Special - V7 Racer Electrical system TABLE E 1. Side stand switch connector TABLE F 1. Starter motor actuator connector 2. Side stand cabling TABLE G Check that the hood which covers the • starter motor positive is inserted well and that the nut is secured correctly to the prescribed torque.
  • Page 70 V7 Stone - V7 Special - V7 Racer Electrical system TABLE H 1. Gear in neutral switch 2. Cable grommet TABLE I 1. Main cable harness 2. Cable ties that secure the main cabling to the frame 3. Left cylinder coil 4.
  • Page 71 V7 Stone - V7 Special - V7 Racer Electrical system TABLE O 1. Neutral switch connector 2. Right Lambda probe connector 3. Cable tie that joins the switch connectors and the right lambda probe TABLE P 1. Battery positive Check the cable which goes from the battery positive to the fuse box to be sure it is covered •...
  • Page 72 V7 Stone - V7 Special - V7 Racer Electrical system TABLE Q 1. Taillight connector 2. Speed sensor connector Hide the taillight and speed sensor • connectors between the filter box and mudguard TABLE R 1. Engine oil bulb 2. Clamp...
  • Page 73 V7 Stone - V7 Special - V7 Racer Electrical system 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 •...
  • Page 74 V7 Stone - V7 Special - V7 Racer Electrical system TABLE W 1. High voltage cable covered by black sheath for right cylinder 2. High voltage cable covered by grey sheath for left cylinder TABLE X 1. Pick Up connector TABLE Y 1.
  • Page 75 V7 Stone - V7 Special - V7 Racer Electrical system Back side CAUTION ONCE THE ELECTRICAL SYSTEM IS REFITTED, THE CONNECTORS RECONNECTED AND CLAMPS AND RETAINERS RESTORED, CARRY OUT THE CHECKS INDICATED UNDER "SPE- CIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES" IN THE "ELEC- TRICAL SYSTEM INSTALLATION"...
  • Page 76 V7 Stone - V7 Special - V7 Racer Electrical system General wiring diagram key: 1. Multiple connectors 2. Air temperature sensor 3. Speed sensor 4. Instrument panel ELE SYS - 76...
  • Page 77 V7 Stone - V7 Special - V7 Racer Electrical system 5. Light relay 6. Starter motor relay 7. Clutch switch 8. Right light switch 9. Horn 10.Left light switch 11.GPS wiring 12.Rear stop switch 13.Front stop switch 14.Ignition switch 15.Rear right turn indicator 16.Stop - position bulb...
  • Page 78 V7 Stone - V7 Special - V7 Racer Electrical system 43.Front position 44.High/low beam bulb 45.Front right turn indicator 46.- 47.- 48.- 49.- 50.- Cable colour: Ar orange Az sky blue B blue Bi white G yellow Gr grey M brown...
  • Page 79 V7 Stone - V7 Special - V7 Racer Electrical system To reset Service proceed as follows: Hold down the key (A). • Turn the ignition key to "ON". • Wait for the Key OFF. • The next time the vehicle is started, the value will be reset and the word "MAInt"...
  • Page 80 V7 Stone - V7 Special - V7 Racer Electrical system 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.
  • Page 81 V7 Stone - V7 Special - V7 Racer Electrical system 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.
  • Page 82 V7 Stone - V7 Special - V7 Racer Electrical system 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)

  • Page 83: Control Unit

    V7 Stone - V7 Special - V7 Racer Electrical system Fuses FUSE DISTRIBUTION A) Stop, daylight running lights, horn (10 A). B) GPS installation, low / high-beam lights, pass- ing (15 A). C) Control unit, engine kill, starter relay, instrument panel, injection load relay (15 A).

  • Page 84: Speed Sensor

    V7 Stone - V7 Special - V7 Racer Electrical system Speed sensor Function To indicate the vehicle speed by reading the rear wheel turning speed. Operation / Operating principle Hall effect sensor: a square-wave pulse is gener- ated with voltage between 12V and approximately 0.6 V.
  • Page 85 V7 Stone - V7 Special - V7 Racer Electrical system Carry out the check on instrument panel PIN 17. • In the event that these checks have not detected the fault, replace the sensor. • Engine rpm sensor Function It informs crankshaft position and speed to the Marelli control unit.
  • Page 86 V7 Stone - V7 Special - V7 Racer Electrical system ELECTRICAL ERRORS Cause Faulty cabling or pick up Troubleshooting An interruption in the sensor circuit has been detected, from PIN 20 to PIN 29 of the control • unit connector.
  • Page 87 V7 Stone - V7 Special - V7 Racer Electrical system Electrical characteristics: Resistance at 0°C: 9.75 k ± 5% • Resistance at 20°C: 3.747 k ± 5% • Resistance at 40°C: 1.598 k ± 5% • Resistance at 60°C: 0.746 k ± 5% •...
  • Page 88 V7 Stone - V7 Special - V7 Racer Electrical system Disconnect the sensor connector. • Check the sensor connector PIN 2 ground insulation. • If there is no ground insulation restore the cabling. • If PIN 2 is insulated from the ground and the error persists, this means that there is a probable •...
  • Page 89 V7 Stone - V7 Special - V7 Racer Electrical system 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.
  • Page 90 V7 Stone - V7 Special - V7 Racer Electrical system Error cause Shorted to positive: excessive voltage at PIN 2 of the control unit connector. Shorted to negative: lack of insulation from ground on the sensor connector PIN 4. The circuit is open: interruption of the circuit.
  • Page 91 V7 Stone - V7 Special - V7 Racer Electrical system 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.
  • Page 92 V7 Stone - V7 Special - V7 Racer Electrical system Disconnect the sensor connector and the control unit connector. • Check the sensor connector PIN 1 ground insulation. In the absence of insulation restore • the cabling. Check the sensor connector PIN 2 ground insulation. In the absence of insulation restore •...
  • Page 93 V7 Stone - V7 Special - V7 Racer Electrical system Injector Function To supply the correct amount of petrol at the right timing. Operation / Operating principle Injector coil is excited for the petrol passage to open. Level in electrical circuit diagram:Coils and in-...
  • Page 94 V7 Stone - V7 Special - V7 Racer Electrical system Shorted to negative: Disconnect the injector connector, turn the key to ON and activate the component through • the diagnostics instrument. Verify the presence of voltage at the ends of the injector connector; if there is no voltage, •...

  • Page 95: Fuel Pump

    V7 Stone - V7 Special - V7 Racer Electrical system Shorted to negative: Disconnect the injector connector, turn the key to ON and activate the component through • the diagnostics instrument. Verify the presence of voltage at the ends of the injector connector; if there is no voltage, •...
  • Page 96 V7 Stone - V7 Special - V7 Racer Electrical system ELECTRICAL ERRORS Fuel pump relay P0230 - shorted to positive / shorted to negative / open circuit. Error cause Shorted to positive: excessive voltage at PIN 22 of the control unit connector.
  • Page 97 V7 Stone - V7 Special - V7 Racer Electrical system Secondary winding resistance: 3 k ± • Tube resistance 5 k • Pin-out: 1. Circuit ground (orange/white cable) 2. Power (red/brown cable) ELECTRICAL ERRORS H.V. Coil P0351 - shorted to positive / open circuit or shorted to negative.
  • Page 98 V7 Stone - V7 Special - V7 Racer Electrical system Disconnect the control unit connector and the coil connector. • Verify the coil connector PIN 1 ground insulation (or control unit connector PIN 1). Restore • the cabling if necessary.
  • Page 99 V7 Stone - V7 Special - V7 Racer Electrical system Verify, with the key turned ON, the presence of voltage on the coil connector PIN 1. If no • voltage is read, verify the continuity of the cabling between coil and injection relay (No. 33 on the electrical circuit diagram): Coil PIN 1 - relay PIN 3.
  • Page 100 V7 Stone - V7 Special - V7 Racer Electrical system Detach the sensor connector and check the purple cable is ground insulated: if there is • continuity to ground, restore the cable harness; if it is ground insulated, replace the switch.
  • Page 101 V7 Stone - V7 Special - V7 Racer Electrical system Restore if damaged. • If OK, check continuity. • If there is no continuity, restore the cabling. • If OK, replace the instrument panel if the vehicle performs properly. •...
  • Page 102 V7 Stone - V7 Special - V7 Racer Electrical system Troubleshooting Verify that, if a gear is engaged, the stand is up. • If it is up, check continuity of the brown/white cable and control unit PIN 14. • If there is no continuity, restore the cabling.
  • Page 103 V7 Stone - V7 Special - V7 Racer Electrical system Side Stand Down: open circuit (infinite • resistance) Pin-out: Blue green (cable harness side): • ground connection Grey yellow (cable harness side): Volt- • age 12V Troubleshooting The vehicle with clutch pulled, gear engaged and side stand retracted does not start (side •...
  • Page 104 V7 Stone - V7 Special - V7 Racer Electrical system 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 •...
  • Page 105 V7 Stone - V7 Special - V7 Racer Electrical system In case there is a short circuit to ground connection of PIN 12 of the instrument panel con- • nector: Check the ground insulation of the sensor connector pink cable: •...
  • Page 106 V7 Stone - V7 Special - V7 Racer Electrical system from ground of the red/yellow cable (cable harness side). If there is continuity with ground connection, restore the cable harness; if it is OK, set the key to KEY OFF and check the control unit connector;...
  • Page 107 V7 Stone - V7 Special - V7 Racer Electrical system 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...
  • Page 108 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 109 V7 Stone - V7 Special - V7 Racer Engine from vehicle RAME pos. Description Type Quantity Torque Notes Screw fixing tank mounting rubber M8x14 25 Nm (18.44 lbf ft) blocks to frame Cradle front fixing screw M10x30 50 Nm (36.88 lbf ft)
  • Page 110 V7 Stone - V7 Special - V7 Racer Engine from vehicle Removing the engine from the vehicle Remove the spark plug covers • Disconnect the caps from the spark • plugs Remove the timing sensor fixing • screws. Remove the sensor, being careful to •...
  • Page 111 V7 Stone - V7 Special - V7 Racer Engine from vehicle Remove the fixing screws of the injec- • tors and disconnect them Disconnect the engine temperature • sensor connector Loosen the clamps securing the sleeve • and remove it Disconnect the oil pressure bulb con- •...
  • Page 112 V7 Stone - V7 Special - V7 Racer Engine from vehicle Remove the fixing screw of the engine • ground wires Disconnect the clutch cable from the • lever Disconnect the clutch cable from the • disengagement lever Pass the rear brake fluid reservoir through the hole on the support of the backing plate.
  • Page 113 V7 Stone - V7 Special - V7 Racer Engine from vehicle Secure the filter box to the frame • Remove the rear brake fluid reservoir fixing screw • Pass the rear brake fluid reservoir through the hole on the support plate bracket.
  • Page 114 V7 Stone - V7 Special - V7 Racer Engine from vehicle Disconnect the side stand switch con- • nector Remove the cradle fixing screws • guards Remove the screws fixing the cradle, • making sure to recover the nuts and...
  • Page 115 V7 Stone - V7 Special - V7 Racer Engine from vehicle Remove the central pin by pulling it • from the right side of the motorcycle Remove the fixing pin of the rear left • shock absorber Remove the screw fixing the right-hand •...
  • Page 116 V7 Stone - V7 Special - V7 Racer Engine from vehicle Lift the frame and separate it from the • engine block Installing the engine to the vehicle Place the frame on the engine block • Insert the central pin from the right side •...
  • Page 117 V7 Stone - V7 Special - V7 Racer Engine from vehicle Insert the screws with the relative re- • tainer nuts and washers of the cradles to the frame Tighten the fixing screws of the cradle to the prescribed torque, the central pin and the side •...
  • Page 118 V7 Stone - V7 Special - V7 Racer Engine from vehicle Connect the side stand switch connec- • Lift the filter box and thread the cable • through the backing plate Connect the neutral sensor connector • Connect the speed sensor and rear stop •...
  • Page 119 V7 Stone - V7 Special - V7 Racer Engine from vehicle Connect the clutch cable to the lever • Install the sleeve, paying attention to • the correct positioning of the clamps before tightening them Connect the oil pressure bulb connec- •...
  • Page 120 V7 Stone - V7 Special - V7 Racer Engine from vehicle Connect the engine temperature sen- • sor connector Connect and secure the injectors • Install the timing sensor with its seal • Connect the alternator connector • ENG VE - 120...
  • Page 121 V7 Stone - V7 Special - V7 Racer Engine from vehicle Connect the spark plug tubes • Install the covers of the spark plugs • ENG VE - 121...
  • Page 122 INDEX OF TOPICS P SUPP OWER SUPPLY...

  • Page 123: Circuit Diagram

    V7 Stone - V7 Special - V7 Racer Power supply Circuit diagram Key: 1. Fuel tank 2. Throttle body 3. Fuel filter 4. Fuel delivery pipe 5. Fuel pump unit Injection P SUPP - 123...
  • Page 124 V7 Stone - V7 Special - V7 Racer Power supply Diagram key: 1. Control unit position 2. Ignition switch 3. Battery 4. Fuel pump 5. Coils 6. Instrument panel 7. Air temperature sensor 8. Throttle valve position sensor 9. Injectors 10.Crankshaft position sensor...
  • Page 125 V7 Stone - V7 Special - V7 Racer Power supply 13.Side stand ECU INFO screen page This screen page shows general data regarding the control unit, for example software type, map- ping, control unit programming date INFO ECU SCREEN PAGE Specification Desc./Quantity...
  • Page 126 INDEX OF TOPICS SUSP USPENSIONS...

  • Page 127: Removing The Front Wheel

    V7 Stone - V7 Special - V7 Racer Suspensions Front RONT WHEEL pos. Description Type Quantity Torque Notes Front wheel axle M18x1.5 80 Nm (59.00 lbf ft) Front brake disc fixing screw M8x20 25 Nm (18.44 lbf ft) Loctite 243...
  • Page 128 V7 Stone - V7 Special - V7 Racer Suspensions ANDLEBAR AND ONTROLS Pos. Description Type Quantity Torque Notes Switch fastener screw SWP 5 1.5 Nm (1.11 lb ft) Counterweight fixing screw 10 Nm (7.37 lb ft) Loctite 243 Screw fastening the clutch control U-bolt to M6x25 10 Nm (7.37 lb ft)
  • Page 129 V7 Stone - V7 Special - V7 Racer Suspensions ANDLEBAR AND ONTROLS Pos. Description Type Quantity Torque Notes Switch fastener screw 1.5 Nm (1.11 lb ft) Tighten using a 1-2-1 se- quence Semi-handlebar fixing screw M6x25 10 Nm (7.37 lb ft)

  • Page 130: Front Fork

    V7 Stone - V7 Special - V7 Racer Suspensions Front fork RONT SUSPENSION TEERING pos. Description Type Quantity Torque Notes Stanchion cap 50 Nm (36.88 lbf ft) Screw fixing wheel axle to right fork leg M6x30 10 Nm (7.37 lbf ft)
  • Page 131 V7 Stone - V7 Special - V7 Racer Suspensions pos. Description Type Quantity Torque Notes Headstock bushing M23x1 50 Nm (36.88 lbf ft) Diagram Key: 1. Screw 2. Washer 3. Screw 4. Complete left sleeve 5. Upper bushing 6. Washer 7.

  • Page 132: Removing The Fork Legs

    V7 Stone - V7 Special - V7 Racer Suspensions 18.Screw 19.Base with headstock 20.Ring nut 21.Fork upper plate 22.Washer 23.Nut 24.Rubber ring 25.Spacer 26.Cap 27.Nut 28.Ring 29.Complete right sleeve 30.Lower U-bolt 31.Upper U-bolt 32.Screw 33.Screw 34.O-ring 35.Stem protection 36.Chrome-plated cap 37.Gasket kit...
  • Page 133 V7 Stone - V7 Special - V7 Racer Suspensions Remove the front mudguard. • Undo and remove the two screws and • collect the washers. Move the instrument panel forwards. • Undo the upper sealing screw. • Undo the lower sealing screw.
  • Page 134 V7 Stone - V7 Special - V7 Racer Suspensions Draining oil To drain out the oil follow these steps. Remove the stanchion. • Tighten the removed stanchion in a • vice fitted with aluminium jaw caps in order to avoid damaging them.
  • Page 135 V7 Stone - V7 Special - V7 Racer Suspensions Remove the shim. • Drain out all the oil inside the stan- • chion. NOTE FOR EASY DRAINAGE OF THE OIL INSIDE THE PISTON ROD, PRESS THE STANCHION IN THE WHEEL HOLDER SLEEVE TO PUMP OIL OUT.
  • Page 136 V7 Stone - V7 Special - V7 Racer Suspensions Disassembling the fork Drain all the oil from the stem. • Block the wheel holder fork leg on the • vice. Undo the bottom screw and remove it • with the corresponding gasket.
  • Page 137 V7 Stone - V7 Special - V7 Racer Suspensions Slide off the bearing tube from the • wheel holder fork leg together with the sealing ring, the cap, the upper bush- ing and lower bushings. NOTE WHEN REMOVING THE PIPE FROM THE WHEEL HOLDER FORK LEG SOME PARTS MAY REMAIN INSIDE THE FORK LEG.
  • Page 138 V7 Stone - V7 Special - V7 Racer Suspensions Check that the upper guide bushing is • fitted on the wheel holder fork leg. Insert the lower sliding bushing in its • seat on the bearing tube. Reassemble the bearing tube in the •...
  • Page 139 V7 Stone - V7 Special - V7 Racer Suspensions Screw the bottom screw and tighten it • to the prescribed torque. Insert the cap and the well-lubricated • sealing ring on the bearing tube. Use a suitable inserting tool to push the •...
  • Page 140 V7 Stone - V7 Special - V7 Racer Suspensions Filling oil Place the sleeve upright in a vice fitted • with protection jaws. Compress the sleeve in the stanchion. • Pour part of the fork oil into the sleeve. •...

  • Page 141: Installing The Fork Legs

    V7 Stone - V7 Special - V7 Racer Suspensions Place the cap on the bearing tube, tak- • ing care not to damage the O-ring. Then, tighten the cap to the prescribed • torque. Installing the fork legs Insert the stem on the vehicle going through the lower plate and the upper plate.
  • Page 142 V7 Stone - V7 Special - V7 Racer Suspensions SUSP - 142...
  • Page 143 V7 Stone - V7 Special - V7 Racer Suspensions Steering bearing RONT SUSPENSION TEERING pos. Description Type Quantity Torque Notes Stanchion cap 50 Nm (36.88 lbf ft) Screw fixing wheel axle to right fork leg M6x30 10 Nm (7.37 lbf ft)
  • Page 144 V7 Stone - V7 Special - V7 Racer Suspensions pos. Description Type Quantity Torque Notes Headstock bushing M23x1 50 Nm (36.88 lbf ft) Adjusting play Undo and remove the screws and col- • lect the U-bolt, holding the handlebar. Move the handlebar forward, be care- •...

  • Page 145: Shock Absorbers

    V7 Stone - V7 Special - V7 Racer Suspensions Adjust the ring nut. • Fit the upper plate on the front fork. • Tighten the central nut. • Working from both sides, tighten the screw locking the upper plate to the front fork.
  • Page 146 V7 Stone - V7 Special - V7 Racer Suspensions (V7 RACER) EAR SUSPENSION pos. Description Type Quantity Torque Notes Upper screw fastening shock absorber to M6x35 10 Nm (7.37 lbf ft) Loctite 243 frame Lower pin fastening left shock absorber to M10x1.5...
  • Page 147 V7 Stone - V7 Special - V7 Racer Suspensions pos. Description Type Quantity Torque Notes Stud bolt fixing right shock absorber to rear M12x1.5 35 Nm (25.81 lbf ft) Screw fastening right shock absorber to stud M6x16 10 Nm (7.37 lbf ft)
  • Page 148 INDEX OF TOPICS CHAS HASSIS...
  • Page 149 V7 Stone - V7 Special - V7 Racer Chassis Swinging arm EAR TRANSMISSION SWINGARM pos. Description Type Quantity Torque Notes Swingarm clamp retaining screw M10x45 30 Nm (22.13 lbf ft) Pin fixing the rear calliper holding M16x1 25 Nm (18.44 lbf ft)
  • Page 150 V7 Stone - V7 Special - V7 Racer Chassis EAR WHEEL pos. Description Type Quantity Torque Notes Rear wheel axle nut M16x1.5 120 Nm (88.51 lb ft) Rear brake disc fixing screw M8x25 25 Nm (18.44 lb ft) Loctite 243 Removing Remove the left silencer.
  • Page 151 V7 Stone - V7 Special - V7 Racer Chassis Remove the rear calliper, releasing the • brake pipe from the retainers on the swingarm. Unscrew and remove the fixing screw • of the calliper holder. Remove both rear suspensions. •...
  • Page 152 V7 Stone - V7 Special - V7 Racer Chassis Loosen the wheel pin locking screw. • Remove the wheel pin and collect the • spacer. Remove the rear wheel. • Unscrew the seal clamp. • Lift the bellows. • CHAS - 152...
  • Page 153 V7 Stone - V7 Special - V7 Racer Chassis Unscrew the nuts. • Loosen the pins so that the oscillating • swingarm can be removed from the gearbox. Remove the shimming washer be- • tween the swingarm right arm and the gearbox.
  • Page 154 V7 Stone - V7 Special - V7 Racer Chassis Installing Insert the swingarm on the gearbox • cover. Tighten thoroughly the pin on the left • side until the shimming washer on the right side rests on the bearing fitted on the gearbox cover.
  • Page 155 V7 Stone - V7 Special - V7 Racer Chassis Fit the rear wheel. • Bevel gears Removing Undo the four nuts and collect the • washers. Slide off the gearcase together with the • swingarm. Slide off the sleeve from the pinion.
  • Page 156 V7 Stone - V7 Special - V7 Racer Chassis Slide off the gear. • Checking Gruppo pignone Remove the housing of the swingarm . • Slide the complete case of the gear- • case. Lock on the vice the sealing tool •...
  • Page 157 V7 Stone - V7 Special - V7 Racer Chassis Slide off the spacer. • Slide off the pinion. • Slide off the shim adjustment washer. • Slide off the O-ring. • Slide off the oil seal. • Slide of the tapered bearing from the •...
  • Page 158 V7 Stone - V7 Special - V7 Racer Chassis Slide off the tapered bearing from the • case. Controllo Check that the pinion toothing is not damaged, worn or deformed; otherwise, replace the • pair. Check that both tapered bearings are not damaged, that the rollers are not damaged or •...
  • Page 159 V7 Stone - V7 Special - V7 Racer Chassis Fit the external ring of the tapered • bearings on the bevel pinion holder case using the suitable punch (19926400). Fit the adjustment shim washer. • Fit the internal ring of the bearing on •...
  • Page 160 V7 Stone - V7 Special - V7 Racer Chassis Fit the complete pinion on the case us- • ing the suitable punch (19926100). Fit the oil seal. • Fit the O-ring. • Fit the spacer. • Insert the grooved shank of the pinion •...
  • Page 161 V7 Stone - V7 Special - V7 Racer Chassis Undo the screws and collect the wash- • ers. Remove the braking disc from the dril- • led bolt. Undo the screws and collect the plates • and the wave washers.
  • Page 162 V7 Stone - V7 Special - V7 Racer Chassis Undo the screws and collect the corre- • sponding safety plates. Remove the conical crown. • Slide off the drilled bolt from the bear- • ing. Remove the sealing ring. •...
  • Page 163 V7 Stone - V7 Special - V7 Racer Chassis Slide off the bearing from the cover us- • ing the suitable punch. Remove the external ring of the needle • bearing from the housing using the suitable extractor (19927500). Remove the sealing ring and the wash- •...
  • Page 164 V7 Stone - V7 Special - V7 Racer Chassis For coupling, proceed as follows: Provisionally lock the complete pinion • case on the housing with two nuts and appropriate spacers. Fit the corresponding tool on the crown • (19928800). Insert the tool on the bearing cage in •...
  • Page 165 V7 Stone - V7 Special - V7 Racer Chassis Fit the drilled bolt-crown unit cover and • their spacers and gaskets on the hous- ing and provisionally tighten the screws. On the crown holder drilled bolt, fit a • "Universal" extractor that with appro- priate central spacers slightly presses the crown towards the brake disc side.
  • Page 166 V7 Stone - V7 Special - V7 Racer Chassis If the contact is like this, the pinion is • too near the rotation axis of the crown: detach the pinion by reducing spacer thickness If the contact is like this, the pinion is •...
  • Page 167 V7 Stone - V7 Special - V7 Racer Chassis Fit the sealing ring on the housing us- • ing the suitable punch (19926000). Fit the external ring of the needle bear- • ing on the housing using the suitable punch (19926500).
  • Page 168 V7 Stone - V7 Special - V7 Racer Chassis Fit the internal ring of the needle bear- • ing on the drilled bolt using the suitable punch (19927900). Insert the sealing ring in the drilled bolt. • Fit the drilled bolt on the cover.
  • Page 169 V7 Stone - V7 Special - V7 Racer Chassis Insert the washer. • Insert the washer. • Fit the O-ring. • Insert the gaskets and the shimming • ring on the cover. Tighten the screws with plates and • washers.
  • Page 170 V7 Stone - V7 Special - V7 Racer Chassis When refitting the bevel pinion case on • the transmission, bear in mind that the oil passage grooves with holes should be fitted vertically (observing the grooves, one should be facing up- wards and the other facing the ground).
  • Page 171 V7 Stone - V7 Special - V7 Racer Chassis Correctly insert the stud bolts of the • gearcase in the holes of the swingarm . Screw the nuts with the washers with- • out locking them. Exhaust XHAUST SYSTEM Pos.
  • Page 172 V7 Stone - V7 Special - V7 Racer Chassis Pos. Description Type Quantity Torque Notes Exhaust pipe fixing clamp screw to 10 Nm (7.37 lb ft) the compensator Compensator fixing clamp screw to 10 Nm (7.37 lb ft) the silencer Lambda probe on compensator M18x1.5...
  • Page 173 V7 Stone - V7 Special - V7 Racer Chassis 15.Right silencer clamp 16.Muffler rubber ring 17.TCEI 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 Removing the tail pipe The engine and the exhaust system components get very hot and remain in this condition for a certain time interval after the engine has been shut off.
  • Page 174 V7 Stone - V7 Special - V7 Racer Chassis Removing the exhaust manifold Remove the exhaust ring fixing nuts, • taking care to recover the washers Remove the spacers • Remove the ring nuts • Remove the starter motor in order to be able to disconnect the left lambda probe connector •...
  • Page 175 V7 Stone - V7 Special - V7 Racer Chassis Disconnect 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 • Removing the lambda sensor Disconnect the left lambda probe (1) and right lambda probe (2) connector.
  • Page 176 INDEX OF TOPICS BODYW ODYWORK...
  • Page 177 V7 Stone - V7 Special - V7 Racer Bodywork ODYWORK RONT SECTION pos. Description Type Quantity Torque Notes Screw fastening stabiliser plate to fork M8x40 15 Nm (11.06 lbf ft) Loctite 243 Screw fastening mudguard to stabiliser M6x11 10 Nm (7.37 lbf ft)
  • Page 178 V7 Stone - V7 Special - V7 Racer Bodywork EAR SECTION BODYWORK ICENSE PLATE MOUNTING pos. Description Type Quantity Torque Notes Screw fastening retroreflector mounting to license M5x10 4 Nm (2.95 lbf ft) plate mounting Nut fixing retroreflector to mounting 4 Nm (2.95 lbf ft)
  • Page 179 V7 Stone - V7 Special - V7 Racer Bodywork ODYWORK CENTRAL SECTION ADDLE pos. Description Type Quantity Torque Notes Saddle release block fixing screw M6x25 10 Nm (2.37 lb ft) Side fairing fixing screw M5x9 4 Nm (2.95 lb ft)
  • Page 180 V7 Stone - V7 Special - V7 Racer Bodywork ODYWORK CENTRAL SECTION ADDLE pos. Description Type Quantity Torque Notes Saddle release block fixing screw M6x25 10 Nm (2.37 lb ft) Throttle body cover fastener screw M5x14 4 Nm (2.95 lb ft)
  • Page 181 V7 Stone - V7 Special - V7 Racer Bodywork Rear mudguard EAR MUDGUARD pos. Description Type Quantity Torque Notes Rear mudguard front and central fixing screw 10 Nm (7.37 lb ft) Rear mudguard side fixing screw M8x30 25 Nm (18.44 lb ft) Screw fixing license plate holder to mudguard 3 Nm (2.21 lb ft)
  • Page 182 V7 Stone - V7 Special - V7 Racer Bodywork 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...
  • Page 183 V7 Stone - V7 Special - V7 Racer Bodywork Remove the rear mudguard by sliding • the light cabling through the wheel housing Splash guard Remove the lower screws (1) • Remove the upper screws (2) taking • care to recover the nuts Remove the splash guard, pulling it to •...

  • Page 184: Fuel Tank

    V7 Stone - V7 Special - V7 Racer Bodywork Fuel tank (V7 RACER) (V7 SPECIAL / V7 STONE) UEL TANK pos. Description Type Quantity Torque Notes Rear tank fixing screw M8x45 25 Nm (18.44 lb ft) BODYW - 184...
  • Page 185 V7 Stone - V7 Special - V7 Racer Bodywork pos. Description Type Quantity Torque Notes Screw fastening cap flange to tank M5x12 4 Nm (2.95 lb ft) (V7 SPECIAL / V7 STONE) Unscrew and remove the rear screw. • Partially lift the fuel tank in order to be •...
  • Page 186 V7 Stone - V7 Special - V7 Racer Bodywork Remove the fuel breather pipe. • Remove the fuel tank by sliding it off and back. • (V7 RACER) Remove the screws that fix the horns. • Unscrew and remove the rear screw.
  • Page 187 V7 Stone - V7 Special - V7 Racer Bodywork Disconnect the connector. • Disconnect the fuel pipe. • Remove the fuel breather pipe. • Remove the fuel tank by sliding it off and back. • BODYW - 187...
  • Page 188 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 189 V7 Stone - V7 Special - V7 Racer Pre-delivery Carry out the listed checks before delivering the motorcycle. WARNING HANDLE FUEL WITH CARE. Aesthetic inspection - Paintwork - Fitting of Plastic Parts - Scratches - Dirt Tightening torques inspection - Safety fasteners:...

  • Page 190: Road Test

    V7 Stone - V7 Special - V7 Racer Pre-delivery - Through the diagnosis tool, check that the last mapping version is present in the control unit/s and, if required, program the control unit/s again: consult the technical service website to know about available upgrades and details regarding the operation.
  • Page 191 V7 Stone - V7 Special - V7 Racer Pre-delivery - Response to throttle control - Stability when accelerating and braking - Front and rear brake efficiency - Front and rear suspension efficiency - Abnormal noise Static test Static check after test drive:...
  • Page 192 V7 Stone - V7 Special - V7 Racer Pre-delivery WO SEATER VERSION pos. Description Type Quantity Torque Notes Passenger handgrip front fixing 10 Nm (7.37 lbf ft) screw Passenger handgrip rear fixing nut 25 Nm (18.44 lbf ft) Passenger footrest mounting bracket M8x16 25 Nm (18.44 lbf ft)
  • Page 193 V7 Stone - V7 Special - V7 Racer Pre-delivery Fit the exhaust mounting plate preset • for fixing the passenger footrest, so as to turn the vehicle into a two seater version. Tighten the three fastener screws to • the specified torque.
  • Page 194 V7 Stone - V7 Special - V7 Racer Pre-delivery Lock the bolt with the Seeger ring. • NOTE REPEAT THE STEPS TO FIT THE PASSENGER FOOTPEG ON THE OPPOSITE SIDE. Rotazione ammortizzatori e posizionamento maniglie passeggero Remove the two shock absorber fixing •...
  • Page 195 V7 Stone - V7 Special - V7 Racer Pre-delivery SADDLE ODYWORK CENTRAL SECTION ADDLE pos. Description Type Quantity Torque Notes Saddle release block fixing screw M6x25 10 Nm (2.37 lb ft) Throttle body cover fastener screw M5x14 4 Nm (2.95 lb ft)
  • Page 196 V7 Stone - V7 Special - V7 Racer Pre-delivery Place the two-seat saddle. • PRE DE - 196...
  • Page 197 Air filter: 45, 50, 51, 54 Air temperature sensor: 103 Battery: 79, 83 Brake: Brake lever: Bulbs: Clutch: 101 Coil: 96 Connectors: 106 ECU: 106, 125 Electrical system: 12, 60, 62, 189 Engine oil: 43 Engine temperature sensor: 86 Exhaust: 171, 174 Exhaust manifold: 174 Filter box: Fork: 130, 132, 136, 137, 141...
  • Page 198 Rear wheel: Recommended products: 36 Run/Stop switch: 105 Saddle: Shock absorbers: 145 Side stand: 102 Side stand sensor: 102 Spark plugs: Speed sensor: 84 Stand: 102 Start-up: 80 Tank: 109, 184 Throttle body: 46, 48 Transmission: 12, 42 Tyres: 14 Warning lights: Wiring diagram: 76...

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