MOTO GUZZI V7 CLASSIC Dokumentacja

SERVICE STATION MANUAL981078V7 Classic

DO NOT FORGET THAT THE TIGHTENING TORQUE OF ALL FASTENING ELEMENTS ONWHEELS, BRAKES, WHEEL SPINDLES AND OTHER SUSPENSION COMPONENTS PLAY A KEYROLE IN

•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 pla

Removing•Undo and remove the upper screw.•Undo and remove the lower screw.V7 Classic SuspensionsSUSP - 101Revente Interdite - Revendita Vietata - Resa

INDEX OF TOPICSCHASSIS CHASRevente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

Swinging armRemoving•Remove the left silencer.•Remove the rear calliper, releasing thebrake pipe from the retainers on theswingarm .•Unscrew and remov

•Unscrew and remove the nut and col-lect the washer.•Loosen the wheel pin locking screw.•Remove the wheel pin and collect thespacer.•Remove the rear w

•Unscrew the seal clamp.•Lift the bellows.•Unscrew the nuts.•Loosen the pins so that the oscillatingswingarm can be removed from thegearbox.•Remove th

•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

•Screw the clamp.•Fit the rear wheel.Bevel gearsRemoving•Undo the four nuts and collect thewashers.•Slide off the gearcase together with theswingarm.V

•Slide off the sleeve from the pinion.•Slide off the spring.•Slide off the sealing ring.•Slide off the base.•Slide off the gear.CheckingPinion unit•Re

•Insert the grooved shank of the pinionon the tool and unscrew the nut.•Slide off the spacer.•Slide off the pinion.•Slide off the shim adjustment wash

This number consists of numbers and letters, as inthe example shown below.ZGULW00008MXXXXXXKEY:ZGU: WMI (World manufacturer identifier) code;LW: model

•Slide of the tapered bearing from thecase.•Slide off the O-ring.•Slide off the spacer.•Slide off the two shim washers.•Slide off the tapered bearing

•Fit the external ring of the taperedbearings on the bevel pinion holdercase using the suitable punch(19926400).•Fit the adjustment shim washer.•Fit t

•Fit both shim washers on the pinion.•Fit the spacer on the pinion.•Fit the O-ring.•Fit the complete pinion on the case us-ing the suitable punch (199

•Insert the grooved shank of the pinionon the tool (19907100) and tighten thenut.Casing unit removal•Undo the screws and collect the wash-ers.•Remove

From the cover, slide off:•The needle bearing.•Remove the internal ring of the needlebearing using a suitable punch(19907000).•Remove the washer.•Remo

•Remove the sealing ring.•Slide off the bearing from the cover us-ing the suitable punch.•Remove the external ring of the needlebearing from the housi

on the housing; the groove for the circlip on the drilled bolt are not worn, deformed or spoiled;otherwise, replace them.•Check that the sealing ring

•Apply suitable colours available in themarket on the pinion teeth.•Fit the drilled bolt-crown unit cover andtheir spacers and gaskets on the hous-ing

•If the contact is like this, the crown istoo near the pinion rotation axis: de-tach the crown by increasing spacerthickness.•If the contact is like t

•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-in

Specification Desc./QuantityStarter ElectronicEngine revs at idle speed 1100 +/- 100 rpmIntake valve clearance 0.10 mm (0.0039 in)Outlet valve clearan

•Fit the internal ring of the needle bear-ing on the drilled bolt using the suitablepunch (19927900).•Insert the sealing ring in the drilled bolt.•Fit

•Fit the plates and tighten the screws.•Insert the washer.•Insert the washer.•Fit the O-ring.•Insert the gaskets and the shimmingring on the cover.•Ti

•Fit the braking disc on the drilled boltby locking the screws with the washersusing a torque wrench.•When refitting the bevel pinion case onthe trans

•Correctly insert the stud bolts of thegearcase in the holes of the swingarm .•Screw the nuts with the washers with-out locking them.V7 Classic Chassi

ExhaustKey:1. Right exhaust pipe2. Left exhaust pipe3. Expansion chamber4. Left silencer clamp5. Gasket6. Spacer7. Ring nut8. Washer9. Nut10.Left sile

20.Clip21.Lambda Probe22.Spacer23.Cap24.Gasket25.Protection26.U-bolt27.TBEI screw28.Bushing29.Insulating washerRemoving the tail pipeThe engine and th

•Unscrew and remove the lambdaprobe.Chassis V7 ClassicCHAS - 126Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

INDEX OF TOPICSBODYWORK BODYWRevente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

Fuel tank•Unscrew and remove the rear screw.•Disconnect the connector.•Disconnect the fuel pipe.•Remove the fuel bleeding pipe.•Remove the fuel tank b

INDEX OF TOPICSPRE-DELIVERYPRE DERevente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

Specification Desc./QuantityRear tail light /stop lights 12 V - 5 / 21 WInstrument panel lighting LEDWARNING LIGHTSSpecification Desc./QuantityGear in

Carry out the listed checks before delivering the vehicle.WARNINGBE EXTREMELY CAUTIOUS WHEN HANDLING FUEL.Aesthetic inspection- Paintwork- Fitting of

- Through the diagnosis tool, check that the last mapping version is present in the control unit/s and, ifrequired, program the control unit/s again:

- Response to throttle control- Stability when accelerating and braking- Front and rear brake efficiency- Front and rear suspension efficiency- Abnorm

AAir filter: 27BBattery: 43Bulbs: CClutch: 57Clutch lever: 57DDisplay: 85EEngine oil: 25, 56FFork: 88, 90, 92, 94, 98Fuel: 128Fuses: 42IIdentification

WWarning lights: Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

Wheels and tyresWHEEL RIMSSpecification Desc./QuantityType with spokes, for tyres with inner tubesFront 2.5''x18''Rear 3.50 x 17&a

SWINGARMName Torque in NmSwingarm on gearbox retainer - M20x1 (2) 0 Nm (0 lbf ft) - in support without preloadingLock nut on pin retainer - M20x1 (2)

Name Torque in NmLever lock spacer retainer - M6x16 (1) 10 Nm (7.37 lbf ft)Rear brake rod lock nut - M6 (1) manualBrake pump retainer - M6x25 (2) 10 N

FINISHINGSName Torque in NmIgnition lock retainer - shear head screw - M8x15 (1) at the point of failureIgnition lock retainer - M8x16 (1) 25 Nm (18.4

Name Torque in NmCover to gearbox fixing screws 10 Nm (7.37 lbf ft)Gearbox to clutch bell cover fixing screws 10 Nm (7.37 lbf ft)Index lever fixing nu

INDEX OF TOPICSSPECIAL TOOLS S-TOOLSRevente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

SERVICE STATIONMANUALV7 ClassicTHE VALUE OF SERVICEOnly the mechanics of the official Moto Guzzi Service Network know this vehicle well, thanks to con

SPECIAL TOOLSStores code Description19.92.61.00 Punch for sealing ring of bevel gear pairpinion19.92.88.00 Bevel gear pair alignment pre-fitting tool1

Stores code Description19.92.64.00 Punch for external ring of tapered bearingon bevel gear pair pinion holding body19.92.65.00 Punch for external ring

INDEX OF TOPICSMAINTENANCE MAINRevente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

Maintenance chartNOTECARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SHOWN IF THE VEHICLEIS USED IN WET OR DUSTY AREAS, OFF ROAD OR FOR SPORTIN

Check• Keep the vehicle upright with both wheels on theground.• Unscrew and remove the cap/dipstick (1).• The level is correct if the oil is close to

Engine oilCheckCAUTIONENGINE MUST BE WARM TO CHECK ENGINE OIL LEVELNOTEDO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT STANDSTILL TO WARM UP THE ENGINE

Replacement•Place a container with + 2000 cm³ (122cu.in) capacity under the drainageplugs (1).•Unscrew and remove the drainageplugs (1).•Unscrew and r

Air filter•Remove the fuel tank.•Disconnect the two horn connectors.•Undo and remove the horn fixingscrew.•Working on both sides, undo and re-move the

•Slide off the air filter casing cover fromthe right side of the vehicle.•Remove the air filter.Braking systemLevel checkBrake fluid check•Place the v

Top-upFront brake:•Unscrew the two screws (1) of thebrake fluid reservoir (2) using a Phillipsscrewdriver.•Lift and remove the cover (3) andscrews (1)

SERVICE STATION MANUALV7 ClassicThis manual provides the main information to carry out regular maintenance operations on your vehicle.This manual is i

Maintenance V7 ClassicMAIN - 30Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

INDEX OF TOPICSELECTRICAL SYSTEM ELE SYSRevente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

Components arrangementKey:1. Instrument panel2. Coil3. Fuel pumpElectrical system V7 ClassicELE SYS - 32Revente Interdite - Revendita Vietata - Resali

4. Throttle potentiometer (TPS)5. Injector6. Fall sensor7. Rear light8. Battery9. Instrument panel air sensor10.Control unit11.Speed sensor12.Intake a

Front sideCAUTIONONCE THE ELECTRICAL SYSTEM IS REFITTED, THE CONNECTORS RECONNECTED ANDCLAMPS AND RETAINERS RESTORED, CARRY OUT THE CHECKS INDICATED U

TABLE CArrange the throttle control transmissions.TABLE DInsert the throttle control and starter transmissionsthrough the cable guide on the steering

•After connecting the quick connectors to the pump, check that it has fitted correctly by pullingthe connector in the opposite direction.Locking torqu

TABLE EClamp the main cable harness onto the central part of the left hand spar with two clamps (3) and onthe pipe joining tube the tank attachment (r

General wiring diagramKey:1. Multiple connectors2. Revolution sensor3. Oil pressure sensor4. Left coilElectrical system V7 ClassicELE SYS - 38Revente

5. Right coil6. Spark plugs7. Left injector8. Right injector9. Fuel pump10.Fuel reserve sensor11.Main injection relay (polarised)12.Secondary injectio

Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

43.Instrument panel44.Speed sensor45.External air temperature thermistor46.Right front turn indicator47.High - low-beam bulb48.Front tail light bulb49

•This is shown only after each start-upfor 5 seconds; afterwards, it will shift tothe standard view.To reset Service proceed as follows:•Hold down the

Specification Desc./QuantityFront daylight running light 12V - 5WTurn indicator light 12 V - 10 W (orange RY 10 W bulb)License plate light 12V - 5 WRe

Control unitMagneti Marelli engine control unit 15 RCBatteryCharacteristicBattery12V - 12 AhSpeed sensorFunctionTo indicate the vehicle speed by readi

PIN:•PINS 1-3 Voltage: approximately 12 V•PINS 2-3 Voltage: between 0.6V-12V(turning the rear wheel)1. Supply voltage (green - sensor side)2. Output s

Pin-out:1. Engine revolution sensor positive signal2. Engine revolution sensor negative signal3. Revolution sensor anti-jamming cableAXONE: PARAMETERS

•sensor: on the right cylinder throttlebody•connector: on the potentiometerElectrical characteristics:PINS A-C: throttle closed approximately 1.7kOhm;

AXONE: ADJUSTABLE PARAMETERSSelf-adjustable parameters reset:Lambda probe: operation to be carried out after the throttle body is cleaned, or in the c

•Orange (cable harness side): 0-5 V sig-nalAXONE: PARAMETERSEngine temperatureIn case of failure, the value read on Axone (20°C - 68°F) is set by the

Air temperature sensorFunctionIt tells the control unit the intake air temperature inorder to calculate oxygen presence so as to opti-mise the petrol

INDEX OF TOPICSCHARACTERISTICS CHARSPECIAL TOOLS S-TOOLSMAINTENANCE MAINELECTRICAL SYSTEM ELE SYSENGINE FROM VEHICLE ENG VEPOWER SUPPLY P SUPPSUSPENSI

nector and the PIN related to the pink/black cable (cable harness side) of the sensor: restorecable harness if there is not continuity; if it is OK, r

1. Sensor signal + (black wire)2. Sensor signal - (grey wire)3. Heater ground connection (white)4. Heater power supply (white)AXONE: PARAMETERSLambda

•Disconnect the connector and check that the heater resistance (on 2 white cables) is ap-proximately 13 Ohm (at room temperature). If it is OK, check

•If shorted to positive: excessive voltage has been detected at PIN 13 of the control unitconnector.•If shorted to negative: no voltage has been detec

with the ground connection, restore the cable harness; if there is not continuity, replace theinjector.•The circuit is open: check the component corre

of the wiring is necessary for correct activation: no error indications are displayed in case of lack ofactivation.AXONE: ELECTRICAL ERRORSLeft coil -

two cable terminals. If there is no continuity, restore the cable harness; if there is cablecontinuity, with key set to ON, check the cable earth insu

Neutral sensorFunctionit tell the gear position to the instrument panel: if it is in neutral or in gear.Operation / Operating principlefor neutral gea

•sensor: under clutch lever•connector: under the fuel tankElectrical characteristics:•Clutch pulled: closed circuit (continuity)•Clutch released: open

•Blue (cable harness side): Ground connection•Green/brown (cable harness side): voltage 12VDIAGNOSIS•The vehicle with clutch pulled, gear engaged and

INDEX OF TOPICSCHARACTERISTICS CHARRevente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

•Pink/yellow (cable harness side): Volt-age 12V•Grey (cable harness side): ground con-nectionDIAGNOSISThe vehicle starts, even if the sensor is invert

"---" code that indicates an instrument panel errorAir temperature sensor faultError cause•An instrument panel temperature sensor failure is

•voltage 0 V with engine kill in STOP;•12 V with engine kill in RUN.Orange/red cable (cable harness side): always voltage 12 V (with key on)DIAGNOSIS•

10.Diagnosis line (L) - Communication line11.Throttle position signal - Analogue input12.Engine revolution sensor - Frequency input13.Right injector c

17.Speed input18.Engine revs input19.n.c.20.Reserve input21.Key22.Ground connection23.Battery24.Front right arrow output25.Rear right arrow output26.B

INDEX OF TOPICSENGINE FROM VEHICLE ENG VERevente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

Vehicle preparation•Before removing the engine block, re-move the fuel tank, the battery, theexhaust pipes, the shock absorbersand the rear wheel.•Dis

•Remove the revolution sensor butkeep it connected to the cable harness.•Slide the pin, with the split pin, fixingthe linkage to the clutch to the eng

•Remove the injectors lock and slide in-jectors off there seat on the inlet mani-folds.•Disconnect the spark plug cables fromthe coils and slide them

•Remove the connection of the enginetemperature sensor.•Disconnect the starter motor and thelambda probe.•Open the clamp and disconnect the oilbreathe

RulesSafety rulesCarbon monoxideIf you need to keep the engine running in order to carry out any procedure, please ensure that you doso in an open or

•Disconnect the neutral indicator.•Disconnect the connector of the sidestand safety switch and slide off thecable harness from the chassis.•Undo and r

•Undo the screw fixing the ground eye-let on the engine block.•Support the vehicle chassis by meansof a hoister.•Undo the four Allen head screws fixin

•During this removal operation, discon-nect the connection of the oil pressuretransmitter.Installing the engine to the vehicle•Secure the scooter chas

•Fit the screw fixing the ground eyeleton the engine block.•Restore the connection of the sidestand safety switch.•Connect the neutral indicator.•Inse

•Connect the starter motor and thelambda probe.•Restore the connection of the enginetemperature sensor.•Insert the breather pipes on the cylin-der hea

•Tighten the clamps on the intake mani-folds.•Insert the injectors in their positionsand fit the locking ring, tightening thescrew to the prescribed t

•Place the clutch linkage and insert thepin on the engine block, locking it withthe corresponding split pin.•Refit the swingarm and the bevel gearpair

•Fit the revolution sensor by tighteningthe screws to the prescribed torque.•Restore the electrical connections ofthe generator.•Restore the connectio

INDEX OF TOPICSPOWER SUPPLY P SUPPRevente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

Circuit diagramKey:1. Fuel tank2. Throttle body3. Fuel filter4. Fuel delivery pipe5. Fuel pump unitInjectionV7 Classic Power supplyP SUPP - 79Revente

BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAINTED SURFACES.WHEN SERVICING THE BRAKING SYSTEM OR THE CLUTCH SYSTEM, PROTECT THESE COM-PO

DiagramKey:1. Control unit position2. Ignition switch3. Battery4. Fuel pump5. Coils6. Instrument panel7. Air temperature sensor8. Throttle valve posit

13.Fall sensor14.Side standCylinders synchronisation•With engine off, connect the Axone2000 tool to the diagnosis connectorand to the vehicle battery.

•Start the engine.•Take the engine to the prescribed tem-perature: 50 °C (122 °F).•Completely close the two by-passscrews on the throttle bodies.•Take

Co rate adjustmentIt is not possible to adjust CO (time of injectors opening) but just resetting the self-adjustable parametersin case the throttle bo

Specification Desc./QuantityLambda integrator When the control unit uses the lambda probe signal (see the'Lambda' parameter on the 'Dev

Devices activation screen pageDEVICES ACTIVATIONThis display is used to delete errors in the controlunit memory and to activate some systems con-troll

Specification Desc./QuantityFuel pump relay Possible short circuit in the earth lead, battery or open circuit:the engine does not start.Self-adjustabl

INDEX OF TOPICSSUSPENSIONS SUSPRevente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

FrontRemoving the front wheel•Place the vehicle on a stable supportso that the front wheel does not touchthe ground.•Remove the brake calliper without

3. Screw4. Complete left sleeve5. Upper bushing6. Washer7. Sealing ring8. Snap ring9. Dust guard10.Stem11.Lower bushing12.Buffer13.Counter spring14.Co

•Keep coupled parts together since they have "adjusted" to each other due to normal wearand tear.•Some components must be used together or r

Removing the fork legsThe vehicle is equipped with a non adjustable fork. The operations described below are valid for bothstems.CAUTIONDURING THE OPE

•Undo the lower sealing screw.•Slide off the stem downwards by turning it slightly first in one direction then to the oppositedirection.Draining oilTo

•Be careful not to damage the O-Ringduring extraction.•Press the bearing tube inside thewheel holder fork leg.•Remove the preload tube and thespring.•

•Remove the dust scraper using ascrewdriver as a lever.CAUTIONBE CAREFUL NOT TO DAMAGE THE FORK LEG RIM ANDTHE DUST SCRAPER.•Slide the dust scraper of

Checking the components•Check every component removed fromthe fork leg, specially: the sealing ringand the dust guard as they are ele-ments that guara

•Insert the lower sliding bushing in itsseat on the bearing tube.•Reassemble the bearing tube in thewheel holder fork leg.•Insert the bearing tube in

•Insert the cap and the well-lubricatedsealing ring on the bearing tube.•Use a suitable inserting tool to push thesealing ring in the fork leg until i

Filling oil•Place the sleeve upright in a vice fittedwith protection jaws.•Compress the sleeve in the stem.•Pour part of the fork oil into the sleeve.

•Place the cap on the bearing tube, tak-ing care not to damage the O-ring.•Then, tighten the cap to the prescribedtorque.Installing the fork legs•Inse

Steering bearingAdjusting play•Undo and remove the screws and col-lect the U-bolt, holding the handlebar.•Move the handlebar forward, be care-ful not