SERVICE STATION MANUAL

898983

V7 Racer
 SERVICE STATION
MANUAL

V7 Racer

THE VALUE OF SERVICE

Only the mechanics of the Official Moto Guzzi Service Network know this vehicle well, thanks to constant
technical professional development and Moto Guzzi specific training programmes, and have the tools
needed to carry out maintenance and repair operations correctly.
The reliability of the vehicle also depends on its mechanical conditions. Checking the vehicle before riding
it, carrying out routine maintenance and using only Moto Guzzi Original Spare parts is fundamental!
For information about the nearest Official Dealer and/or Service Centre, consult the Yellow Pages or
search directly on the inset map in our Official Website:
www.motoguzzi.it
Only by purchasing Moto Guzzi Original Spare Parts will you get a product designed and tested during
the bike designing phase. Moto Guzzi Original Spare Parts are subject to systematic quality control
procedures so that their reliability and performance over time is guaranteed.
The descriptions and illustrations given in this publication are not binding; While the basic features as
described and illustrated in this booklet remain unchanged, Moto Guzzi reserves the right, at any time
and without being required to update this publication beforehand, to make any changes to components,
parts or accessory supplies, which it deems necessary to improve the product or which are required for
manufacturing or commercial reasons.
Not all versions/models shown in this publication are available in all countries. The availability of individual
versions should be checked with the Official Moto Guzzi sales network.
© Copyright 2010- Moto Guzzi. All rights reserved. Reproduction of this publication in whole or in part is
prohibited. Moto Guzzi - After sales service.
The Moto Guzzi trademark is the property of Piaggio & C. S.p.A.
 SERVICE STATION MANUAL
V7 Racer
This manual provides the main information to carry out regular maintenance operations on your scooter.
This manual is intended to Moto Guzzi Dealers and their qualified mechanics; several concepts have
been deliberately omitted as they are considered unnecessary. As it is not possible to include complete
mechanical notions in this manual, users should have basic mechanical knowledge or minimum
knowledge about the procedures involved when repairing scooters. Without this knowledge, repairing or
checking the vehicle may be inefficient or even dangerous. As the vehicle repair and check procedures
are not described in detail, be extremely cautious so as not to damage components or injure individuals.
In order to optimise customer satisfaction when using our vehicles, Moto Guzzi s.p.a. commits itself to
continually improve its products and the relative documentation. The main technical modifications and
changes in repair procedures are communicated to all Moto Guzzi Sales Outlets and its International
Subsidiaries. These changes will be introduced in the subsequent editions of the manual. In case of
need or further queries on repair and check procedures, consult Moto Guzzi CUSTOMER
DEPARTMENT, which will be prepared to provide any information on the subject and any further
communications on updates and technical changes related to the vehicle.

NOTE Provides key information to make the procedure easier to understand and carry out.

CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.

WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.

Personal safety Failure to completely observe these instructions will result in serious risk of personal
injury.

Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle
to prevent damaging the environment.

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
INDEX OF TOPICS

CHARACTERISTICS 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
INDEX OF TOPICS

CHARACTERISTICS CHAR
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 run the engine in an enclosed area. If you do work in an
enclosed area, make sure to use a fume extraction system.
CAUTION

EXHAUST EMISSIONS CONTAIN CARBON MONOXIDE, A POISONOUS GAS WHICH CAN CAUSE
LOSS OF CONSCIOUSNESS AND EVEN DEATH.
Fuel
CAUTION

THE FUEL USED TO POWER INTERNAL COMBUSTION ENGINES IS HIGHLY FLAMMABLE AND
MAY BE EXPLOSIVE UNDER CERTAIN CONDITIONS. IT IS THEREFORE RECOMMENDED TO
CARRY OUT REFUELLING AND MAINTENANCE PROCEDURES IN A VENTILATED AREA WITH
THE ENGINE SWITCHED OFF. DO NOT SMOKE DURING REFUELLING AND NEAR FUEL VA-
POURS, AVOIDING ANY 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 exhaust system have cooled down.

Used engine oil and transmission oil

CAUTION

IT IS ADVISABLE TO WEAR PROTECTIVE IMPERMEABLE GLOVES WHEN SERVICING THE VE-

HICLE.
THE ENGINE OR GEARBOX OIL MAY CAUSE SERIOUS INJURIES TO THE SKIN IF HANDLED
FOR PROLONGED PERIODS OF TIME AND ON A REGULAR BASIS.
WASH YOUR HANDS CAREFULLY AFTER HANDLING OIL.
HAND THE OIL OVER TO OR HAVE IT COLLECTED BY THE NEAREST USED OIL RECYCLING
COMPANY OR THE SUPPLIER.
DO NOT DISPOSE OF OIL IN THE ENVIRONMENT
KEEP OUT OF THE REACH OF CHILDREN

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Characteristics V7 Racer

Brake and clutch fluid

BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAINTED SURFACES.
WHEN SERVICING THE BRAKING SYSTEM OR THE CLUTCH SYSTEM, PROTECT THESE COM-
PONENTS WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING
THESE SYSTEMS. BRAKE AND CLUTCH FLUIDS ARE EXTREMELY HARMFUL FOR YOUR
EYES. IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THEM IMMEDIATELY
WITH ABUNDANT COLD, CLEAN WATER AND SEEK MEDICAL ADVICE.
KEEP OUT OF THE REACH OF CHILDREN
Battery electrolyte and hydrogen gas
CAUTION

THE BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND AS IT CONTAINS SULPHURIC ACID,

IT CAN CAUSE BURNS WHEN IN CONTACT WITH THE SKIN. WHEN HANDLING BATTERY
ELECTROLYTE, WEAR TIGHT-FITTING GLOVES AND PROTECTIVE APPAREL. IN THE EVENT
OF SKIN CONTACT WITH THE ELECTROLYTIC FLUID, RINSE WELL WITH PLENTY OF CLEAN
WATER. IT IS PARTICULARLY IMPORTANT TO PROTECT YOUR EYES BECAUSE EVEN TINY
AMOUNTS OF BATTERY ACID MAY CAUSE BLINDNESS. IF THE FLUID 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 PLASTIC
COMPONENTS. ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BAT-
TERY TO BE ACTIVATED.

Maintenance rules

GENERAL PRECAUTIONS AND INFORMATION

When repairing, dismantling and reassembling the vehicle, follow the recommendations given below
carefully.

BEFORE DISASSEMBLING COMPONENTS

• Before dismantling components, remove dirt, mud, dust and foreign bodies from the vehicle.
Use the special tools designed for this bike, as required.

COMPONENTS REMOVAL

• Do not loosen and/or tighten screws and nuts using pliers or any other tools than the specific
wrench.
• Mark positions on all connection joints (pipes, cables etc.) before separating them, and
identify them with distinctive symbols.
• Each component needs to be clearly marked to enable identification during reassembly.
• Clean and wash the dismantled components carefully using a low-flammability detergent.
• Keep mated parts together since they have "adjusted" to each other due to normal wear.

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V7 Racer Characteristics

• Some components must be used together or replaced completely.

• Keep away from heat sources.

REASSEMBLING COMPONENTS
CAUTION
BEARINGS MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE, THEY
NEED TO BE REPLACED.
• Only use ORIGINAL Moto Guzzi SPARE PARTS.
• Comply with lubricant and consumables use guidelines.
• Lubricate parts (whenever possible) before reassembling them.
• When tightening nuts and screws, start from the ones with the largest section or from the
internal ones, moving diagonally. Tighten nuts and screws in successive steps before ap-
plying the tightening torque.
• Always replace self-locking nuts, washers, sealing rings, circlips, O-rings (OR), split pins
and screws with new ones if their tread is damaged.
• When assembling the bearings, make sure to lubricate them well.
• Check that each component is assembled correctly.
• After a repair or routine maintenance procedure, carry out pre-ride checks and test the ve-
hicle on private grounds or in an area with low traffic density.
• Clean all coupling surfaces, oil guard rims and gaskets 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).

ELECTRICAL 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 relative safety clips, if applicable.
• Grip the two connectors and disconnect them by pulling them in opposite directions.
• If any signs of dirt, rust, moisture, etc. are noted, clean the inside of the connector carefully
with a jet of compressed air.
• Ensure that the cables are correctly fastened to the internal connector terminals.
• Then connect the two connectors, ensuring that they couple correctly (if fitted with clips, you
will hear them "click" into place).
CAUTION
DO NOT DISCONNECT CONNECTORS BY PULLING THE CABLES.
NOTE
THE TWO CONNECTORS CAN ONLY BE CONNECTED IN ONE DIRECTION: CONNECT THEM
THE RIGHT WAY ROUND.
TIGHTENING TORQUES
CAUTION
IN THE EVENT THAT A SELFBRAKING NUT IS UNSCREWED, IT IS NECESSARY TO REPLACE
IT WITH A NEW ONE.
CAUTION

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Characteristics V7 Racer

REMEMBER THAT THE TIGHTENING TORQUES FOR ALL FASTENING ELEMENTS ON WHEELS,
BRAKES, WHEEL AXLES AND ANY OTHER SUSPENSION COMPONENTS PLAY A KEY ROLE
IN ENSURING VEHICLE SAFETY AND MUST COMPLY WITH SPECIFIED VALUES. CHECK THE
TIGHTENING TORQUES OF FASTENING ELEMENTS ON A REGULAR BASIS AND ALWAYS USE
A TORQUE WRENCH TO REASSEMBLE THESE COMPONENTS. FAILURE TO COMPLY WITH
THESE RECOMMENDATIONS MAY CAUSE ONE OF THESE COMPONENTS TO LOOSEN OR
EVEN DETACH, CAUSING A WHEEL TO LOCK OR COMPROMISING VEHICLE HANDLING. THIS
MAY LEAD TO FALLS, WITH THE RISK OF SERIOUS INJURY OR DEATH.

Running-in

Running the engine in correctly is essential for ensuring engine longevity and functionality. Twisty roads
and gradients are ideal for running in the engine, brakes and suspension effectively. Vary your riding
speed during the running in period. This ensures that components operate in "loaded" conditions and
then "unloaded" conditions, allowing the engine components to cool.
CAUTION
THE CLUTCH MAY EMIT A SLIGHT BURNING SMELL WHEN FIRST USED. THIS PHENOMENON
SHOULD BE CONSIDERED NORMAL AND WILL DISAPPEAR AS SOON AS THE CLUTCH
PLATES GET ADAPTED.
IT IS IMPORTANT TO STRAIN ENGINE COMPONENTS DURING RUN-IN, HOWEVER, MAKE SURE
NOT TO OVERDO THIS.
CAUTION
THE FULL PERFORMANCE OF THE VEHICLE IS ONLY AVAILABLE AFTER THE SERVICE AT
THE END OF THE RUNNING IN PERIOD.
Follow the guidelines detailed below:

• Do not fully open the throttle grip abruptly at low engine speeds, either during or after the
running in period.
• During the first 100 Km (62 miles) use the brakes gently, avoiding sudden or prolonged
braking. 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.

Vehicle identification

SERIAL NUMBER LOCATION

These numbers are necessary for vehicle registration.
NOTE
ALTERING IDENTIFICATION NUMBERS MAY BE SERIOUSLY PUNISHABLE BY LAW. IN PAR-
TICULAR, MODIFYING THE FRAME NUMBER IMMEDIATELY VOIDS THE WARRANTY.

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V7 Racer Characteristics

This number consists of numbers and letters, as in

the example shown below.
ZGULWB0009MXXXXXX
KEY:
ZGU: WMI (World manufacturer identifier) code;
LW: model;
B00: version variation;
0: free digit
9: variable year of manufacture (9 - for 2009)
M: production plant (M= Mandello del Lario);
XXXXXX: serial number (6 digits);
CHASSIS NUMBER
The chassis number is stamped on the right hand
side of the headstock.

ENGINE NUMBER
The engine number 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 2185 mm (86 in)
Max. width 28.74 in (730 mm)
Max. height 1115 mm (43.9 in)
Saddle height 805 mm (31.69 in)
Wheelbase 1435 mm (56.5 in)
Minimum ground clearance 182 mm (7.16 in)
Kerb weight 198 kg (436 lb)

Engine

ENGINE
Specification Desc./Quantity
Type traverse-mounted twin-cylinder four-stroke V 90°
No. of cylinders 2
Engine capacity 744 cm³ (45.40 cu.in)
Bore / stroke 80x74 mm (3.14x2.91 in)
Compression ratio 9.6 : 1

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Characteristics V7 Racer

Specification Desc./Quantity
Electric Electric starter
Engine idle speed 1100 +/- 100 rpm
Intake valve clearance 0.15 mm (0.0059 in)
Exhaust valve clearance 0.20 mm (0.0079 in)
Clutch dry single-disc clutch with flexible coupling
Lubrication Pressure-fed, controlled by valves and trochoidal pump
Air filter cartridge-type dry filter
Cooling air

Transmission

TRANSMISSION
Specification Desc./Quantity
Gearbox / Type mechanical, 5 speeds with foot lever on the left-hand side of
the engine.
Primary drive with gears, ratio: 16 / 21 = 1 : 1.3125
Gear ratios, 1st gear 11 / 26 = 1 : 2.3636
Gear ratios, 2nd gear 14 / 23 = 1 : 1.6429
Gear ratios, 3rd gear 18 / 23 = 1 : 1.2778
Gear ratios, 4th gear 18 / 19 = 1 : 1.0556
Gear ratios, 5th gear 22 / 25 = 1 : 0.9
Final drive with cardan shaft, ratio: 8 / 33 = 1 : 4.825

Capacities

CAPACITY
Specification Desc./Quantity
Fuel (reserve included) 15 l (3.30 UKgal; 3.96 USgal)
Fuel reserve 2.5 l (0.55 UK gal; 0.66 USgal)
Engine oil oil change and oil filter replacement: 1780 cm³ (108.62 cu.in)
Gearbox oil 1 l (0.26 USgal)
Transmission oil 170 cm³ (10.37 cu.in)
Seats 1*
Maximum carrying load 203 kg (447 lb) (rider + passenger + luggage)
* 2, if the vehicle is equipped with the long, two-seater saddle
and passenger footpegs. In this case, the user is required to
contact the relevant local authorities for information concerning
the actions necessary to amend the vehicle registration docu-
ments appropriately.

Electrical system

ELECTRICAL SYSTEM
Specification Desc./Quantity
Battery 12V - 12 Ah
Fuses 3- 15- 30 A
Generator (alternator + rectifier) 12V - 350 W

SPARK PLUGS
Specification Desc./Quantity
Standard NGK BR8ES
Alternatively: NGK BR9ES
Spark plug electrode gap 0.6 - 0.7 mm (0.024 - 0.027 in)
Resistance 5 kOhm

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V7 Racer Characteristics

BULBS
Specification Desc./Quantity
Low/high beam light (halogen) 12 V - 55 W / 60 W H4
Front daylight running lights 12V - 5W
Turn indicator light 12 V - 10 W (orange RY 10 W bulb)
tail light /stop lights 12 V - 5 / 21 W
Dashboard lighting LED

WARNING LIGHTS
Specification Desc./Quantity
Gear in neutral LED
Turn indicators LED
Fuel reserve LED
High beam light LED
Engine oil pressure LED
Injection check warning light LED

Frame and suspensions

CHASSIS
Specification Desc./Quantity
Type Modular double cradle, high strength steel tubular chassis
Steering rake 27.5°
Trail 138 mm (5.43 in)

SUSPENSIONS
Specification Desc./Quantity
Front hydraulic telescopic fork, Ø 40 mm (1.57 in)
Travel 130 mm (5.12 in)
Rear die-cast light alloy swingarm with 2 adjustable shock absorbers
Wheel travel 100 mm (3.93 in)

SIZES A AND B
Specification Desc./Quantity
Size A 692 mm (27.24 in)
Size B 186 mm (7.32 in)

Brakes

BRAKES
Specification Desc./Quantity
Front stainless steel floating disc, Ø 320 mm (12.59 in), callipers with
4 different and counteracting plungers

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Characteristics V7 Racer

Specification Desc./Quantity
Rear 260 mm (10.24 in) diam. stainless steel disc

Wheels and tyres

WHEEL RIMS
Specification Desc./Quantity
Type with spokes, for tyres with inner tubes
Front 2.5''x18''
Rear 3.50 x 17''

TYRES
Specification Desc./Quantity
Front tyre (standard) PIRELLI SPORT DEMON
Front tyre (alternative) METZELER LASERTEC
Front (size) 100 / 90 - 18 56H TL
Front (inflation pressure) 2.2 bar (220 kPa) (31.90 PSI)
Front (inflation pressure with passenger) 2.5 bar (250 kPa) (36.3 PSI)
Rear tyre (standard) PIRELLI SPORT DEMON
Rear tyre (alternative) METZELER LASERTEC
Rear (size) 130 / 80 - 17 65H TL
Rear (inflation pressure) 2.2 bar (220 kPa) (31.90 PSI)
Rear (inflation pressure with passenger) 2.5 bar (250 kPa) (36.3 PSI)

Supply

FUEL SYSTEM
Specification Desc./Quantity
Type electronic injection (Weber - Marelli)
Diffuser Ø 36 mm (1.42 in)
Fuel Premium unleaded petrol, minimum octane rating of 95
(NORM) and 85 (NOMM)

Tightening Torques

Chassis

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V7 Racer Characteristics

Front side

FRONT SUSPENSION - STEERING

pos. Description Type Quantity Torque Notes
1 Stanchion cap - 2 50 Nm (36.88 lbf ft) -
2 Screw fixing wheel axle to right fork leg M6x30 2 10 Nm (7.37 lbf ft) Tighten using a 1-2-1 se-
quence
3 Screw fixing stanchions to upper and lower M10x40 4 50 Nm (36.88 lbf ft) -
plate
4 Headstock ring nut M25x1 1 7 Nm (5.16 lbf ft) The fork must fall to one
side by itself

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Characteristics V7 Racer

pos. Description Type Quantity Torque Notes

5 Headstock bushing M23x1 1 50 Nm (36.88 lbf ft) -

INSTRUMENT PANEL
pos. Description Type Quantity Torque Notes
1 Screw fixing instrument panel to headlamp sup- M6x10 3 10 Nm (7.37 lbf ft) -
port

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V7 Racer Characteristics

HANDLEBAR AND CONTROLS

Pos. Description Type Quantity Torque Notes
1 Switch fastener screw M5 1+1 1.5 Nm (1.11 lb ft) Tighten using a 1-2-1 se-
quence
2 Semi-handlebar fixing screw M6x25 4 10 Nm (7.37 lb ft) Tighten using a 1-2-1 se-
quence
3 Counterweight fixing screw M6 2 10 Nm (7.37 lb ft) Loctite 243
4 Screw fastening the clutch control U-bolt to M6x25 2 10 Nm (7.37 lb ft) Tighten using a 1-2-1 se-
the semi-handlebar quence

FRONT BRAKE SYSTEM

pos. Description Type Quantity Torque Notes
1 Screw fastening the brake pump U-bolt to the M6 2 10 Nm (7.37 lbf ft) Tighten using a 1-2-1 se-
semi-handlebar quence
2 Front brake calliper fixing screw M10x30 2 50 Nm (36.88 lb ft) -
3 Drilled screw for brake fluid pipe on pump and - 2 25 Nm (18.44 lb ft) -
calliper

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Characteristics V7 Racer

FRONT LIGHTS
pos. Description Type Quantity Torque Notes
1 Headlamp fixing screw M8x30 2 15 Nm (11.06 lb ft) -
2 Front turn indicator fixing screw M6 2 5 Nm (3.69 lb ft) -
3 Horn fixing screw M6x16 2 10 Nm (7.37 lb ft) -
4 Headlamp support bracket fixing M10x40 2 50 Nm (36.88 lb ft) -
screw

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V7 Racer Characteristics

BODYWORK - FRONT SECTION

pos. Description Type Quantity Torque Notes
1 Screw fastening stabiliser plate to fork M8x40 4 15 Nm (11.06 lbf ft) Loctite 243
2 Screw fastening mudguard to stabiliser M6x11 4 10 Nm (7.37 lbf ft) Loctite 243
plate
3 Top fairing fixing screw M6 2 10 Nm (7.37 lbf ft)

FRONT WHEEL
pos. Description Type Quantity Torque Notes
1 Front wheel axle M18x1.5 1 80 Nm (59.00 lbf ft) -
2 Front brake disc fixing screw M8x20 6 25 Nm (18.44 lbf ft) Loctite 243

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Characteristics V7 Racer

ELECTRICAL SYSTEM (FRONT)

pos. Description Type Quantity Torque Notes
1 HV coil fastener screw M4x25 4 3 Nm (2.21 lbf ft) -
2 Timing sensor fastener screw M5x12 2 6 Nm (4.42 lbf ft) -

Central part

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V7 Racer Characteristics

FRAME
pos. Description Type Quantity Torque Notes
1 Screw fixing tank mounting rubber M8x14 2 25 Nm (18.44 lbf ft) -
blocks to frame
2 Cradle front fixing screw M10x30 4 50 Nm (36.88 lbf ft) -
3 Screw fastening gearbox to frame M10x55 2 50 Nm (36.88 lbf ft) -
4 Pin fixing engine/gearbox to chassis M10x205 1 50 Nm (36.88 lbf ft) -
5 Screw fixing exhaust silencer mount- M8x16 4 25 Nm (18.44 lbf ft) Loctite 243
ing to frame
6 Battery supporting plate fixing screw M8x16 4 25 Nm (18.44 lbf ft) -

FRAME CRADLES
pos. Description Type Quantity Torque Notes
1 Screw fixing stand beam to cradle M10x260 1 50 Nm (36.88 lbf ft) -
2 Screw fixing stand beam to cradle M8 1+1 25 Nm (18.44 lbf ft) -
3 Pin fixing engine/gearbox to chassis M10x250 1 50 Nm (36.88 lbf ft) -
4 Screw fastening cradle to frame M10x65 2 50 Nm (36.88 lbf ft) -

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Characteristics V7 Racer

SIDE STAND
pos. Description Type Quantity Torque Notes
1 Side stand retainer pin M10x1.2 1 10 Nm (7.38 lb ft) -
5
2 Lock nut for stand bolt M10x1.2 1 30 Nm (22.13 lb ft) -
5
3 Switch fixing screw M5x16 2 6 Nm (4.42 lb ft) -

FUEL TANK
pos. Description Type Quantity Torque Notes
1 Rear tank fixing screw M8x45 1 25 Nm (18.44 lb ft) -
2 Screw fastening cap flange to tank M5x12 2+3 4 Nm (2.95 lb ft) -

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V7 Racer Characteristics

FUEL SUPPLY SYSTEM

pos. Description Type Quantity Torque Notes
1 Screw fixing fuel pump mounting to M5x16 6 6 Nm (4.43 lbf ft) -
tank

AIR FILTER
pos. Description Type Quantity Torque Notes
1 Air filter box cover fastening screw SWP M5x20 3 3 Nm (2.21 lbf ft) -

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Characteristics V7 Racer

pos. Description Type Quantity Torque Notes

2 Air filter box half-shells and cover Self-tapp. 3.9x14 12 3 Nm (2.21 lbf ft) -
fastening screw
3 Screw fastening air filter box to frame SWP M5x20 3 3 Nm (2.21 lbf ft) -

GEAR SHIFT
pos. Description Type Quantity Torque Notes
1 Screw fastening left hand rider foot- M8x20 2 25 Nm (18.44 lb ft) Loctite 243
rest mounting plate to cradle
2 Preselector lever fixing screw M6x20 1 10 Nm (7.37 lb ft) -
3 Gearbox lever fixing screws M6x20 1 10 Nm (7.37 lb ft) Loctite 243
4 Gearbox control rod fixing nut M6x1 1 10 Nm (7.37 lb ft) -
5 Screw fastening rider footrest mount- M8 1 20 Nm (14.75 lb ft) Loctite 243
ing to plate

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V7 Racer Characteristics

REAR BRAKE LEVER

pos. Description Type Quantity Torque Notes
1 Screw fastening right hand rider foot- M8x20 2 20 Nm (14.75 lb ft) Loctite 243
rest mounting plate to cradle
2 Rear brake lever fixing screw M6x20 1 10 Nm (7.37 lb ft) Loctite 243
3 Screw fastening rider footrest mount- M8 1 25 Nm (18.44 lb ft) Loctite 243
ing to plate
4 Rear brake pump fixing screw M6x25 2 8 Nm (5.90 lb ft) Loctite 243
5 Rear brake fluid reservoir fixing M5x15 1 6 Nm (4.43 lb ft) -
screw
6 Nut fastening rod terminal on brake M6 1 10 Nm (7.37 lb ft) -
lever

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Characteristics V7 Racer

BODYWORK CENTRAL SECTION - SADDLE

pos. Description Type Quantity Torque Notes
1 Saddle release block fixing screw M6x25 2 10 Nm (2.37 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) -

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LOCK KIT
pos. Description Type Quantity Torque Notes
1 (Shear head) screw fixing ignition M8x15 1 - At the point of failure
lock
2 Ignition lock fixing screw M8x16 1 25 Nm (18.44 lb ft) -

EXHAUST SYSTEM
Pos. Description Type Quantity Torque Notes
1 Exhaust pipe fixing nut to the engine M6 4 10 Nm (7.37 lb ft) -
2 Exhaust pipe fixing clamp screw to M6 1+1 10 Nm (7.37 lb ft) -
the compensator
3 Compensator fixing clamp screw to M6 2 10 Nm (7.37 lb ft) -
the silencer
4 Lambda probe on compensator M18x1.5 1 38 Nm (28.03 lb ft) -
5 Nut fastening silencer to mounting M8 4 25 Nm (18.44 lb ft) -
plate
6 Heat shield fixing screw M6x12 6 10 Nm (7.37 lb ft) Loctite 270
7 Screw fixing silencer mounting plate M8x40 2 25 Nm (18.44 lb ft) -
to frame

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Characteristics V7 Racer

Back side

REAR TRANSMISSION - SWINGARM

pos. Description Type Quantity Torque Notes
1 Swingarm clamp retaining screw M10x45 1 30 Nm (22.13 lbf ft) -
2 Pin fixing the rear calliper holding M16x1 1 25 Nm (18.44 lbf ft) -
plate to swingarm
3 Nut fixing gearcase to swingarm M8 4 25 Nm (18.44 lbf 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 lbf ft) Hold the pin

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V7 Racer Characteristics

REAR SUSPENSION
pos. Description Type Quantity Torque Notes
1 Upper screw fastening shock absorber to M6x35 2 10 Nm (7.37 lbf ft) Loctite 243
frame
2 Lower pin fastening left shock absorber to M10x1.5 1 35 Nm (25.81 lbf ft)
swingarm
3 Stud bolt fixing right shock absorber to rear M12x1.5 1 35 Nm (25.81 lbf ft) -
box
4 Screw fastening right shock absorber to stud M6x16 1 10 Nm (7.37 lbf ft) Loctite 243
bolt

CHAR - 29
Characteristics V7 Racer

REAR WHEEL
pos. Description Type Quantity Torque Notes
1 Rear wheel axle nut M16x1.5 1 120 Nm (88.51 lb ft) -
2 Rear brake disc fixing screw M8x25 6 25 Nm (18.44 lb ft) Loctite 243

REAR BRAKE SYSTEM

pos. Description Type Quantity Torque Notes
1 Rear brake calliper fixing screw M8x35 2 25 Nm (18.44 lbf ft) -

CHAR - 30
V7 Racer Characteristics

pos. Description Type Quantity Torque Notes

2 Drilled screw for brake pipe on cal- - 1 25 Nm (18.44 lb ft) -
liper
3 Stud bolt fixing right shock absorber - 1 25 Nm (18.44 lbf ft) -
to rear box

REAR LIGHTS
pos. Description Type Quantity Torque Notes
1 Screw fastening taillight support to M5x14 3 4 Nm (2.95 lb ft) -
mudguard
2 Rear turn indicator fixing screw M6 2 5 Nm (3.69 lb ft) -

CHAR - 31
Characteristics V7 Racer

REAR SECTION BODYWORK - LICENSE PLATE MOUNTING

pos. Description Type Quantity Torque Notes
1 Screw fastening retroreflector mounting to license M5x10 2 4 Nm (2.95 lbf ft) -
plate mounting
2 Nut fixing retroreflector to mounting M5 1 4 Nm (2.95 lbf ft) -

CHAR - 32
V7 Racer Characteristics

REAR MUDGUARD
pos. Description Type Quantity Torque Notes
1 Rear mudguard front and central fixing screw M6 2+1 10 Nm (7.37 lb ft)
2 Rear mudguard side fixing screw M8x30 2 25 Nm (18.44 lb ft)
3 Screw fixing license plate holder to mudguard SWP 3 3 Nm (2.21 lb ft)
reinforcement M5x20

ELECTRICAL SYSTEM (REAR)

pos. Description Type Quantity Torque Notes
1 Air temperature sensor fastener Self-tapp. 2.9x12 2 2 Nm (1.47 lbf ft) -
screw
2 Electronic control unit fixing screw SWP M5x20 4 3 Nm (2.21 lbf ft) -
3 Speedometer sensor fastener screw M6x12 1 10 Nm (7.37 lbf ft) -
4 Fuse box bracket fixing screw M5x12 2 4 Nm (2.95 lbf ft) -
5 Battery mount bracket fixing screw SWP M5x20 3 3 Nm (2.21 lbf ft) -

CHAR - 33
Characteristics V7 Racer

TWO SEATER VERSION

pos. Description Type Quantity Torque Notes
1 Passenger handgrip front fixing M6 2 10 Nm (7.37 lbf ft) -
screw
2 Passenger handgrip rear fixing nut M8 2 25 Nm (18.44 lbf ft) -
3 Passenger footrest mounting bracket M8x16 4 25 Nm (18.44 lbf ft) Loctite 243
fixing screw
4 Countersunk-head Allen screw M8 2 25 Nm (18.44 lbf ft) -

Recommended products chart

RECOMMENDED PRODUCTS TABLE

Product Description Specifications
ENI i-RIDE PG 10W-60 Lubricant formulated with advanced syn- JASO MA, MA2 - API SG
thetic technology and high performance
additives to cater specifically for 4-stroke
engines with high specific power outputs.
AGIP GEAR MG SAE 85W-140 Transmission oil API GL-4 and GL-5
AGIP GEAR MG/S SAE 85 W-90 Gearbox oil API GL-5
AGIP FORK 7.5W Fork oil SAE 5W / SAE 20W
AGIP GREASE SM 2 Gray black smooth-textured lithium -
grease, containing molybdenum disul-
phide.
Neutral grease or petroleum jelly. Battery poles
AGIP 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.

CHAR - 34
INDEX OF TOPICS

SPECIAL TOOLS S-TOOLS

Special tools V7 Racer

SPECIAL TOOLS
Stores code Description
19.92.61.00 Punch for seal ring of bevel gear set pin-
ion

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 Extractor for external ring of gearcase

bearing

19.92.62.00 Punch for bearing on bevel gear set pin-

ion

S-TOOLS - 36
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-

ing

19.92.76.00 Extractor for swinging arm holder bearing

on gearbox cover

S-TOOLS - 37
INDEX OF TOPICS

MAINTENANCE MAIN
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.
I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY
V: CHECK AND CLEAN, ADJUST AND REPLACE IF NECESSARY
C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE
(1) Check and clean, adjust or replace, if necessary, every 1,000 Km (621 mi)
(2) Replace every 2 years or 20000 Km (12427 mi).
(3) Replace every 4 years.
(4) At each engine start.
(5) Check every month.

ROUTINE MAINTENANCE TABLE

km x 1,000 1 7.5 15 22.5 30 37.5 45 52.5 60
Spark plugs R R R R R R R R
Carburetion at idle (CO) I I I I I I I I
Transmission cables and controls I I I I I I I I I
Steering bearings and steering clearance I I I I I I I I I
Wheel bearings I I I I I I I I
Brake discs I I I I I I I I I
Air filter I R I R I R I R
Engine oil filter R R R R R R R R R
Fork I I I I I
Lights operation / aiming I I I I I I I I
Vehicle general operation I I I I I I I I I
Braking systems I I I I I I I I I
Light circuit I I I I I I I I I
Safety switches I I I I I I I I I
Brake fluid (2) I I I I I I I I I
Gearbox oil R R R R R R R R R
Fork oil / oil seals R R R
Engine oil R R R R R R R R R
Final drive oil R R R R R R R R R
Tyres - pressure/wear (5) I I I I I I I I I
Engine idle speed A A A A A A A A A
Valve clearance adjustment A A A A A A A A A
Wheels I I I I I I I I I
Bolts and nuts tightening I I I I I I I I I
Battery terminals tightening I
Head screws tightening A
Cylinder synchronisation I I I I I I I I I
Suspension and setting I I I I I
Engine oil pressure warning light (4)
Fuel lines (3) I I I I I I I I
Brake lines (3) I I I I I I I I
Clutch wear I I I I I I I I
Brake pad wear (1) V V V V V V V V V
Labour time (minutes) 130 190 130 190 130 130 190 130 130

MAIN - 39
Maintenance V7 Racer

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).
• If the oil is lower than specified, top-up until it
reaches the cap/dipstick hole (1).
CAUTION

DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCE TO

THE FLUID. WHEN USING A FUNNEL OR ANY OTHER EL-
EMENT, MAKE SURE IT IS PERFECTLY CLEAN.

Replacement
CAUTION
THE UNIT MUST BE HOT WHEN THE OIL IS CHANGED AS UNDER SUCH CONDITIONS OIL IS
FLUID AND THEREFORE EASY TO DRAIN.
NOTE
RIDE SOME km (miles) TO WARM UP ENGINE OIL
• Place a container with + 400 cm³ (25 cu in) capacity under the drainage plug (3).
• Unscrew and remove the drainage plug (3).
• Unscrew and remove the breather cap (2).
• Drain the oil into the container; allow several minutes for oil to drain out completely.
• Check and if necessary, replace the sealing washer of drainage plug (3).
• Remove any metal scrap attached to the drainage plug (3) magnet.
• Screw and tighten the drainage plug (3).
• Pour new oil through the fill opening (1) until it reaches the cap/dipstick hole (1).
CAUTION
DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCE TO THE FLUID. WHEN USING A FUNNEL
OR ANY OTHER ELEMENT, MAKE SURE IT IS PERFECTLY CLEAN.

MAIN - 40
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
OIL AND REACH THE OPERATING TEMPERATURE OF ENGINE OIL. OIL IS BEST CHECKED
AFTER 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 level is correct when it close to the "MAX" mark.

MAX = maximum level

MIN = minimum level
Add engine oil if required:

• Unscrew and remove the cap with dipstick.

• Top-up with engine oil until it goes above the minimum level marked "MIN".

MAIN - 41
Maintenance V7 Racer

CAUTION
DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCE TO
THE FLUID. WHEN USING A FUNNEL OR ANY OTHER EL-
EMENT, MAKE SURE IT IS PERFECTLY CLEAN.

Replacement

• Place a container with + 2000 cm³ (122

cu.in) capacity under the drainage
plugs (1).
• Unscrew and remove the drainage
plugs (1).
• Unscrew and remove the filler cap (2).
• Drain the oil into the container; allow
several minutes for oil to drain out com-
pletely.
• Check and if necessary, replace the
sealing washers of drainage plugs (1).
• Remove any metal scrap attached to
the magnet of drainage plugs (1).
• Screw and tighten the drainage plugs
(1).

Drainage plugs tightening torque (1): 12 Nm

(1.2 kgm)

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.

MAIN - 42
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.
• Fit the new engine oil filter with the spring facing downwards.
• Refit the cover (4), screw and tighten the screw (3)

Air filter

• Remove the fuel tank.

• Disconnect the two horn connectors.

• Undo and remove the horn fixing

screw.

MAIN - 43
Maintenance V7 Racer

• Working on both sides, undo and re-

move the two air filter casing cover
screws.

• Remove the oil breather pipe.

• Slide off the air filter casing cover from

the right side of the vehicle.

• Remove the air filter.

MAIN - 44
V7 Racer Maintenance

Braking system

FRONT BRAKE SYSTEM

pos. Description Type Quantity Torque Notes
1 Screw fastening the brake pump U-bolt to the M6 2 10 Nm (7.37 lbf ft) Tighten using a 1-2-1 se-
semi-handlebar quence
2 Front brake calliper fixing screw M10x30 2 50 Nm (36.88 lb ft) -
3 Drilled screw for brake fluid pipe on pump and - 2 25 Nm (18.44 lb ft) -
calliper

MAIN - 45
Maintenance V7 Racer

REAR BRAKE SYSTEM

pos. Description Type Quantity Torque Notes
1 Rear brake calliper fixing screw M8x35 2 25 Nm (18.44 lbf ft) -
2 Drilled screw for brake pipe on cal- - 1 25 Nm (18.44 lb ft) -
liper
3 Stud bolt fixing right shock absorber - 1 25 Nm (18.44 lbf ft) -
to rear box

Level check

Brake fluid check

• Rest the vehicle on its stand.

• For the front brake, turn the handlebar fully to the right.
• For the rear brake, keep the vehicle upright so that the fluid in the reservoir is at the same
level with the plug.
• Make sure that the fluid level in the reservoir is above the "MIN" reference mark:

MIN = minimum level

MAX = maximum level
If the fluid does not reach at least the "MIN" reference mark:

• Check brake pads and disc for wear.

• If the pads and/or the disc do not need replacing, top-up the fluid.

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 the cap (5).

• Remove the gasket (6).
• Top-up the reservoir with brake fluid to
the correct level, which is between the
two "MIN" and "MAX" reference marks.

MAIN - 46
V7 Racer Maintenance

RISK OF BRAKE FLUID SPILLS. DO NOT OPERATE THE

BRAKE LEVER WITH BRAKE FLUID RESERVOIR CAP
LOOSENED OR REMOVED.
CAUTION

AVOID PROLONGED AIR EXPOSURE OF THE BRAKE

FLUID. BRAKE FLUID IS HYGROSCOPIC AND ABSORBS
MOISTURE WHEN IN CONTACT WITH AIR. LEAVE THE
BRAKE FLUID RESERVOIR OPEN ONLY FOR THE TIME
NEEDED TO COMPLETE THE TOPPING UP PROCEDURE.

TO AVOID SPILLING FLUID WHILE TOPPING-UP, KEEP

THE TANK PARALLEL TO THE RESERVOIR EDGE (IN
HORIZONTAL POSITION).

DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCE 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 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 - 47
INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

V7 Racer Electrical system

ELECTRICAL SYSTEM (FRONT)

pos. Description Type Quantity Torque Notes
1 HV coil fastener screw M4x25 4 3 Nm (2.21 lbf ft) -
2 Timing sensor fastener screw M5x12 2 6 Nm (4.42 lbf ft) -

ELECTRICAL SYSTEM (REAR)

pos. Description Type Quantity Torque Notes
1 Air temperature sensor fastener Self-tapp. 2.9x12 2 2 Nm (1.47 lbf ft) -
screw

ELE SYS - 49
Electrical system V7 Racer

pos. Description Type Quantity Torque Notes

2 Electronic control unit fixing screw SWP M5x20 4 3 Nm (2.21 lbf ft) -
3 Speedometer sensor fastener screw M6x12 1 10 Nm (7.37 lbf ft) -
4 Fuse box bracket fixing screw M5x12 2 4 Nm (2.95 lbf ft) -
5 Battery mount bracket fixing screw SWP M5x20 3 3 Nm (2.21 lbf ft) -

Components arrangement

Key:

ELE SYS - 50
V7 Racer Electrical system

1. Instrument panel
2. Coil
3. Fuel pump
4. Throttle potentiometer (TPS)
5. Injector
6. Fall sensor
7. Rear light
8. Battery
9. Instrument panel air sensor
10.Control unit
11.Speed sensor
12.Intake air temperature sensor
13.Engine revolution sensor
14.Head temperature sensor
15.Auxiliary fuses
16.Starter motor
17.Lambda Probe
18.Voltage regulator
19.Oil pressure sensor
20.Generator
21.FRONT HEADLAMP

Electrical system installation

INTRODUCTION
Scope and applicability
The purpose of this document is to define cables
laying, their fastening on the motorcycle and pos-
sible criticalities, special checks on connections
and layouts, all this with the aim of obtaining vehi-
cle reliability.
Special checks for the correct connection and
laying of cables
The indicated connectors are considered critical in
comparison with the others because the vehicle
will stop if they are accidentally disconnected. Un-
doubtedly the connection of the rest of connectors

ELE SYS - 51
Electrical system V7 Racer

is also important and essential for the correct op-

eration of the vehicle.
Vehicle sections
The wiring distribution is subdivided in three es-
sential sections, as indicated in the figure.

1. Front section
2. Central section
3. Rear section

Front side

FRONT SECTION
TABLE A
Connect the instrument panel to the main cable
harness (1), passing it over the headlight support
bracket (2).
Clamp the main cable harness to the headlight
support bracket with a clamp (3).

TABLE B
Connect the turn indicators and the temperature
sensor to the main system and clamp them as in-
dicated.

TABLE C
Arrange the throttle control transmissions.

ELE SYS - 52
V7 Racer Electrical system

TABLE D
Insert the throttle control and starter transmissions
through the cable guide on the steering pipe (4)
and fasten them with a rubber clamp (5).

TABLE E
Turn the steering to the left, clamp the three cables
of the front cable harness with two clamps:

• the first clamp fixed to the chassis in

the opening;
• the second, near the headstock.

Central part

CENTRAL SECTION
TABLE A - TANK FITTING

• Place the submersible pump and set the six screws, tightening them in a criss-cross se-
quence to the prescribed torque.
• Repeat the tightening sequence.
• After connecting the quick connectors to the pump, check that it has fitted correctly by pulling
the connector in the opposite direction.

Locking torques (N*m)

Pump support to tank retainer - M5x16 (6) 6 Nm (4.42 lbf ft)

ELE SYS - 53
Electrical system V7 Racer

TABLE B
Clamp the tank drainage pipes to the ground with
the oil scavenge pipes so that they do not touch
the compensator.
CAUTION
DO NOT SQUEEZE THE TWO TUBES WHILE FASTENING
THE CLAMP.

TABLE C - RELAY POSITION

1. Relay with five pins (tank side)
2. Relay with four pins in third position.

TABLE D - FASTENING THE ELECTRICAL

SYSTEM TO THE CHASSIS
Position the electrical system on the chassis, hold-
ing the red strap at the centre of the rear coil, and
fix with a clamp.
WARNING
THE CLAMP MUST BE POSITIONED BEHIND THE REAR
COIL, SO THAT THE SYSTEM CANNOT SLIDE FOR-
WARDS.

TABLE E
Clamp the main cable harness onto the central part of the left hand spar with two clamps (3) and on
the pipe joining tube the tank attachment (right side) (4) with one clamp.

ELE SYS - 54
V7 Racer Electrical system

TABLE F - TIMING SWITCH SYSTEM POSITION

Clamp the timing sensor system to the generator
system, regulator system, horn system and left ca-
ble of the chassis cross member.
CAUTION
DO NOT SQUEEZE THE TWO TUBES WHILE FASTENING
THE CLAMP.

TABLE G - TIMING SWITCH SYSTEM POSI-

TION
Clamp the timing sensor connector to the left hand
side of the chassis, positioning it as far as possible
from the coil and the spark plug cables.

ELE SYS - 55
Electrical system V7 Racer

General wiring diagram

Key:

1. Multiple connectors
2. Revolution sensor
3. Oil pressure sensor
4. Left coil

ELE SYS - 56
V7 Racer Electrical system

5. Right coil
6. Spark plugs
7. Left injector
8. Right injector
9. Fuel pump
10.Fuel reserve sensor
11.Main injection relay (polarised)
12.Secondary injection relay
13.Side stand switch
14.Lambda Probe
15.Throttle sensor
16.Engine air thermistor
17.Head temperature sensor
18.Voltage regulator
19.FLYWHEEL
20.Battery
21.Starter motor
22.Main fuses
23.Auxiliary fuses
24.License plate light
25.Right rear turn indicator
26.Tail light - Stop bulb
27.Rear light
28.Right rear turn indicator
29.Key switch
30.Front stop switch
31.Rear stop switch
32.Right light switch
33.Left light switch
34.Horn
35.Clutch switch
36.Start-up relay
37.Light relay
38.-
39.-
40.Diode
41.Gear in neutral switch
42.Fall sensor

ELE SYS - 57
Electrical system V7 Racer

43.Instrument panel
44.Speed sensor
45.External air temperature thermistor
46.Right front turn indicator
47.High - low-beam bulb
48.Front tail light bulb
49.Front headlamp
50.Left front turn indicator
51.ECU
52.Diagnostics socket

Cable colour:
Ar orange
Az sky blue
B blue
Bi white
G yellow
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.

ELE SYS - 58
V7 Racer Electrical system

• This is shown only after each start-up

for 5 seconds; afterwards, it will shift to
the standard view.

To reset Service proceed as follows:

• Hold down the key (A).

• Turn the ignition key to "ON".
• Wait for the Key OFF.

The next time the vehicle is started, the value will

be reset and the word "MAInt" will not be displayed
until the next mileage for which maintenance is
foreseen.

Start-up system check

pick-up input about 100 A

level indicators

Petrol pump:
Input 4A (to be measured between pins 1 and 2
with 12V supply voltage)
Fuel level sensor:
Resistance 1.4 Ohm (to be measured between
pins 3 and 4 with fuel level equal to 0 litres)

Lights list

BULBS
Specification Desc./Quantity
Low/high beam light (halogen) 12 V - 55 W / 60 W H4

ELE SYS - 59
Electrical system V7 Racer

Specification Desc./Quantity
Front daylight running lights 12V - 5W
Turn indicator light 12 V - 10 W (orange RY 10 W bulb)
License plate light 12V - 5 W
tail light /stop lights 12 V - 5 / 21 W
Dashboard lighting LED

Fuses

FUSE DISTRIBUTION
A) High-beam / low-beam lights, start-up (15 A).
B) Stop lights, tail lights, horn, turn indicators (15
A).
C) From battery to injection permanent power sup-
ply (3 A).
D) Injection services (15 A).
E) Main fuse (30 A).
F) Battery recharge (30 A).

ELE SYS - 60
V7 Racer Electrical system

Control unit

Magneti Marelli engine control unit 15 RC

Battery

Characteristic
Battery
12V - 12 Ah

Speed sensor

Function
To indicate the vehicle speed by reading the rear
wheel rotation speed.
Operation / Operating principle
Hall effect sensor: a square-wave pulse is gener-
ated with voltage between 12V and approximately
0.6 V.
Level in wiring diagram:
Speed sensor
Location:

• Sensor: on the swingarm, left side,

next to the rear brake calliper.
• connector: under right fairing, next to
the Marelli control unit.

Pin-out:

ELE SYS - 61
Electrical system V7 Racer

PIN:

• PINS 1-3 Voltage: approximately 12 V

• PINS 2-3 Voltage: between 0.6V-12V
(turning the rear wheel)

1. Supply voltage (green - sensor side)

2. Output signal (grey/white - sensor side)
3. Ground (blue/orange - sensor side)

DIAGNOSIS
Speed viewing problems on the instrument panel
CARRY OUT THE CASCADE OPERATIONS UNTIL THE FAILURE IS FOUND
- Check correct position of the sensor in its fitting.
- Check voltage between PINS 1-3 of the sensor. If there is no voltage, check continuity between PIN
1 of the sensor and PIN 3 of the instrument panel connector.
- Check the instrument panel PIN 13 connector.
- Check continuity with the sensor PIN 13 ground lead.
- Check continuity of the grey/white cable harness (cable harness side) from PIN 2 of the sensor to PIN
17 of the instrument panel connector.
- Check instrument panel PIN 17. If there is no failure after all these checks, replace the sensor.

Engine rpm sensor

Function
It informs crankshaft position and speed to the
Marelli control unit.
Operation / Operating principle
Inductive sensor: sinusoidal-type generated volt-
age; two teeth are missing on the flywheel for the
reference position.
Level in electrical circuit diagram:engine speed
sensor
Location:

• Sensor: engine front left section, under

the left cylinder.
• Connector: under the fuel tank.

Electrical characteristics:

ELE SYS - 62
V7 Racer Electrical system

• Winding resistance: 650 Ω ± 15% Out-

put alternating voltage, value range:
minimum: 0.5 V - maximum: 5 V

Pin-out:

1. Engine speed sensor positive signal

2. Engine speed sensor negative signal
3. Engine speed sensor anti-jamming cable

NAVIGATOR: PARAMETERS
Target engine revs
Example value:1100 +/- 100 rpm
Parameter valid at idle, setting depends especially on engine temperature: the ECU unit will try to keep
the engine running at this revs, acting on the ignition advance.
NAVIGATOR: STATUSES
Synchronisation
Example value:Synchronised / Not synchronised
Indicates if the control unit detects the engine speed sensor signal correctly

DIAGNOSIS
Engine speed sensor
An interruption in the sensor circuit has been detected, from PIN 7 to PIN 12 of the control unit connector.
Check the sensor connector and the injection ECU connector: if not OK, restore; if OK, check continuity
of the two cables to PINS 7 and 12 of the control unit connector: if there is no continuity, restore the
cable harness; if there is continuity, check the interruption on the sensor and replace it
CAUTION If the electric circuit is short-circuited, no error is displayed. Check the sensor electrical
specifications: If it is not the correct one, replace the sensor. If it is the correct one, check supply insu-
lation and ground connection insulation of both cables. Carry out the tests from the sensor connector
to the sensor. If not OK, restore the cable harness or replace the sensor. If OK, perform the test from
pins 7 and 12 of the Marelli control unit connector to the cable harness.
Installation
Place the sensor plus the corresponding spacers; the air gap should be between 0.7 and 0.9 mm.

ELE SYS - 63
Electrical system V7 Racer

Throttle position sensor

Function
In charge of telling the control unit the position of
the throttle valves.
Operation / Operating principle
The throttle valve position sensor works as a var-
iable resistance according to the throttle rotation.
Level in electrical circuit diagram:Throttle and
idle motor
Location:

• sensor: on the right cylinder throttle

body
• connector: on the potentiometer

Electrical characteristics:
PINS A-C: throttle closed approximately 1.7
kOhm; throttle open approximately 1.1 kOhm.
PINS A-B: approximately 1 kOhm.
Pin-out:
a: ground connection
B: supply voltage +5V
C: potentiometer signal (from 0.5 V with closed
throttle to 4 V with open throttle)
NAVIGATOR: PARAMETERS
Potentiometer on throttle / 0.5 (minimum) - 4 (full load)
Correct throttle position / 3.1 (minimum) - 85 (full load)
NAVIGATOR: STATUSES
Minimum/full load - ON/OFF
If the throttle is at minimum, it indicates ON, if the throttle is out of minimum, it indicates OFF
NAVIGATOR: ELECTRICAL ERRORS
Throttle - open circuit, shorted to positive / shorted to negative.
Error cause
• If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 11 of
the control unit connector.
• If shorted to negative: voltage equal to zero has been detected.
Troubleshooting
• Circuit is open, shorted to positive: check the injection control unit connector and the sensor
connector: if they are not OK, restore; if they are OK, check the continuity between PIN 11

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of the control unit connector and PIN C of the sensor (brown/yellow cable): if there is not
continuity, restore the cable harness; if there is continuity, check continuity of the sensor
between PIN A and PIN C: if there is not continuity, replace the potentiometer; if there is
continuity, measure the resistance. If resistance is over 2 kOhm, it indicates the brown/yellow
cable is shorted to positive; therefore, it is necessary to restore cable harness
• shorted to negative: disconnect the sensor connector and check ground insulation of the
brown/yellow cable (from throttle sensor connector or control unit connector): if there is
continuity with the ground connection, restore the cable harness; if isolated from ground
connection, the resistance between PIN A and PIN C is below 1.3 kOhm; therefore, it is
necessary to replace the throttle body.

NAVIGATOR: ADJUSTABLE PARAMETERS

Self-adjustable parameters reset:
Lambda probe: operation to be carried out after the throttle body is cleaned, or in the case a new engine,
a new lambda probe or a new injector is fitted, or the correct operation of the injection system or the
valves is restored.
Throttle positioner self-acquisition:
Allows the control unit to detect the closed throttle position: just press the enter button. The operation
should be carried out when the throttle body of the throttle position sensor or the injection control unit
is replaced
RESET PROCEDURE:
Once the throttle body or the injection control unit is replaced, it is necessary to connect to the diagnosis
instrument selecting FUEL INJECTION and carry out the operation: Throttle positioner self-acquisition

Engine temperature sensor

Function
indicates the engine temperature to the control unit
so as to optimise carburetion and idle control
Operation / Operating principle
NTC type sensor (resistance sensor, inversely
variable with temperature).
Level in electrical circuit diagram:Temperature
sensors
Location:

• on the right head, next to the throttle

body
• connector: on the sensor

Electrical characteristics:

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• Resistance at 0°C: 9.75 kΩ ± 5%

• Resistance at 20°C: 3.747 kΩ ± 5%
• Resistance at 40°C: 1.598 kΩ ± 5%
• Resistance at 60°C: 0.746 kΩ ± 5%
• Resistance at 80°C: 0.377 kΩ ± 5%
• Resistance at 100°C: 0.204 kΩ ± 5%

Pin-out:

• Grey (cable harness side): Ground

connection
• Orange (cable harness side): 0-5 V sig-
nal

NAVIGATOR: PARAMETERS
Engine temperature
In case of failure, the value read on Navigator (20°C - 68°F) is set by the control unit, so it is not a real
value.
NAVIGATOR: ELECTRICAL ERRORS
engine temperature sensor - open circuit, shorted to positive / shorted to negative.
Error cause

• If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 4 of
the control unit connector.
• If shorted to negative: voltage equal to zero has been detected at PIN 4 of the control unit
connector

Troubleshooting

• If the circuit is open, shorted to positive: check sensor connector and Marelli control unit
connector; if not OK, restore cable harness; if OK, check sensor continuity; if it is not OK,
replace the sensor; if it is OK, check continuity between PIN 4 of the control unit connector
and the PIN marked by the orange cable of the sensor: restore cable harness if there is not
continuity; if it is OK, reconnect the control unit connector and, with key set to ON, check
continuity between the PIN marked by the grey cable of the sensor connector and the vehicle
ground connection: if there is not continuity, restore cable harness; if there is continuity, it
means that the error cause is a shorted-to-positive cable; therefore, restore cable harness
between PIN 4 of the control unit and the PIN marked by the orange cable of the sensor. If
the engine air temperature sensor error is displayed at the same time, it means that there
is a short circuit to positive in the grey cable of both sensors.
• If shorted to negative, check sensor correct resistance: if resistance = 0, replace the sensor;
if resistance is correct, it means that the cable has ground connection: restore the cable
harness.

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Air temperature sensor

Function
It tells the control unit the intake air temperature in
order to calculate oxygen presence so as to opti-
mise the petrol quantity necessary for correct com-
bustion.
Operation / Operating principle
NTC type sensor (resistance sensor, inversely
variable with temperature).
Level in electrical circuit diagram:Temperature
sensors
Location:

• sensor: on the right side of the filter

box, next to the control unit
• connector: on the sensor

Electrical characteristics:

• Resistance at 0°: 9.75 kΩ ± 5%

• Resistance at 10°: 5.970 kΩ ± 5%
• Resistance at 20°: 3.747 kΩ ± 5%
• Resistance at 25°: 3.000 kΩ ± 5%
• Resistance at 30°: 2.417 kΩ ± 5%

Pin-out:

• Grey (cable harness side): Ground connection

• Pink/black (cable harness side): 0-5 V signal

NAVIGATOR:PARAMETERS
Air temperature
In case of failure, the value set by the control unit is 20 °C (68 °F)
NAVIGATOR: ELECTRICAL ERRORS
air temperature sensor open circuit, shorted to positive / shorted to negative.
Error cause

• If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 18 of
the control unit connector.
• If shorted to negative: voltage equal to zero has been detected at PIN 18 of the control unit
connector

Troubleshooting

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• If the circuit is open, shorted to positive: check sensor connector and Marelli control unit
connector; if not OK, restore cable harness; if OK, check sensor continuity; if it is not OK,
replace the sensor; if it is OK, check the continuity between PIN 18 of the control unit con-
nector and the PIN related to the pink/black cable (cable harness side) of the sensor: restore
cable harness if there is not continuity; if it is OK, reconnect the control unit connector and,
with key set to ON, check continuity between the PIN related to the grey cable (cable harness
side) of the sensor and the vehicle ground connection: if there is not continuity, restore cable
harness; if there is continuity, it means that the error cause is a shorted-to-positive cable;
therefore, restore cable harness between PIN 18 of the control unit and the PIN related to
the pink/black cable (cable harness side) of the sensor. If the engine temperature sensor
error is displayed at the same time, it means that there is short circuit to positive in the grey
cable of both sensors.
• If shorted to negative, check sensor correct resistance: if resistance = 0, replace the sensor;
if resistance is correct, it means that the pink/black cable has ground connection: restore
the cable harness

NOTES No error is detected if the sensor does not work correctly or the control unit connector or sensor
terminals are rusty: then check through Navigator if the temperature indicated is plausible in relation to
the ambient temperature. Check also that the sensor electrical characteristics are observed: replace
the sensor if not OK; if it is OK, check the sensor connector and the Marelli control unit connector

Lambda sensor

Function
In charge of telling the control unit whether the
mixture is lean or rich.
Operation / Operating principle
The Marelli injection control unit reads 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:Lambda
probe
Location:

• sensor: exhaust pipe

• connector: next to the starter motor

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Electrical characteristics:
Heater circuit: 12 -14 Ω at 20 °C (68 °F)
Pin-out:

1. Sensor signal + (black wire)

2. Sensor signal - (grey wire)
3. Heater ground connection (white)
4. Heater power supply (white)

NAVIGATOR: PARAMETERS
Lambda probe
Example value: 0 - 1000 mV
If there is a short circuit at + 5 V or higher, the read value is equal to approximately 1250 mV (the
corresponding error will be displayed on the Navigator). If there is a short circuit on ground connection,
the read value is equal to 0 mV and the Lambda sensor correction parameter indicates 1.5: no error is
displayed, though.
Lambda integrator
example value: 1.00
In closed loop, the value must be close to 1.0 (values not within the 0.7 - 1.3 interval indicate a fault).
In an open circuit, the lambda probe signal is too low. Therefore, the control unit takes it as a lean
combustion condition and will try to enrich it. The value read will be 1.5

NAVIGATOR: STATUSES
Lambda check
Example value: Open loop / Closed loop
Closed loop indicates that the control unit is using the lambda probe signal to keep the combustion as
close as possible to the stoichiometric value.

NAVIGATOR: ELECTRICAL ERRORS

Lambda probe - Generic error.
Error cause
• If shorted to positive: excessive voltage (battery voltage) has been detected at PIN 8 or PIN
2 of the control unit connector.

Troubleshooting
• shorted to positive: with key set to ON, disconnect the sensor connector and measure PIN
1 voltage (pink/yellow cable) on the cable harness side: if there is voltage (5 or 12 V), restore
cable harness; if there is no voltage, measure voltage at PIN 2 on the cable harness side
(green/yellow cable); and if there is voltage, restore cable harness; if there is no voltage,
replace the lambda probe. After the cable harness has been restored or the probe replaced,
the lambda probe error will remain active until an operation cycle is completed

Lambda probe heating - Lambda probe that does not get into cycle

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Error cause
• Short circuit/open circuit: lambda probe that does not get into cycle.
Troubleshooting
• Disconnect the connector and check that the heater resistance (on 2 white cables) is ap-
proximately 13 Ohm (at room temperature). If it is OK, check if there is ground connection
on PIN 4 (blue cable) on the cable harness side; if OK, check if there is battery voltage on
PIN 3 (red/brown cable) on the cable harness side for 2 seconds upon "key ON" and after-
wards when the engine is started.

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-
jectors
Location:

• on the intake manifolds

• connector: on injector

Electrical characteristics:14.8 Ohm +/- 5% (at

20 °C - 68 °F)
Pin-out:

1. Ground connection
2. Power supply 12V
NAVIGATOR:PARAMETERS
• Left cylinder injection time
• Right cylinder injection time
NAVIGATOR: ACTIVATION
Left injector: operation for 4 ms, 5 times
The auxiliary injection relay (No. 12 in the wiring diagram, placed under saddle, second relay starting
from the front; CHECK, however, the identification of the relay with the colour of the cables) is energised
for 5 seconds and the grey/red cable of the injector is closed to ground for 4 ms per second. Disconnect
the 4-way connector of the fuel pump to be able to hear the relay and injector activation. The continuity
of the wiring is necessary for correct activation: no error indications are displayed in case of lack of
activation

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NAVIGATOR: ELECTRICAL ERRORS

Left injector - shorted to positive / shorted to negative / open circuit.
Error cause

• If shorted to positive: excessive voltage has been detected at PIN 13 of the control unit
connector.
• If shorted to negative: no voltage has been detected.
• If the circuit is open: an interruption has been detected

Troubleshooting

• Shorted to positive: disconnect the injector connector, take the key to ON and check if there
is voltage on the grey/red cable: if there is voltage, restore the cable harness. If there is no
voltage, replace the injector.
• If shorted to negative: disconnect the injector connector, take the key to ON and check if the
grey/red cable has continuity to the ground connection: if there is continuity to ground, re-
store the cable harness; if there is not continuity, replace the injector
• The circuit is open: check the component correct electrical characteristic: if it is not the cor-
rect one, replace the component; if it is correct, check the connector on the component and
the Marelli control unit connector: If it is not OK, restore; if it is OK, check continuity of the
cable between PIN 13 of the control unit connector and PIN 1 of the component and restore
the cable harness

NAVIGATOR: ACTIVATION
Right injector: operation for 4 ms, 5 times
The auxiliary injection relay (No. 12 in the wiring diagram, placed under saddle, second relay starting
from the front; CHECK, however, the identification of the relay with the colour of the cables) is energised
for 5 seconds and the blue/red cable of the injector is closed to ground for 4 ms per second. Disconnect
the 4-way connector of the fuel pump to be able to hear the relay and injector activation. The continuity
of the wiring is necessary for correct activation: no error indications are displayed in case of lack of
activation
NAVIGATOR: ELECTRICAL ERRORS
Right injector - shorted to positive / shorted to negative / open circuit.
Error cause

• If shorted to positive: excessive voltage has been detected at PIN 6 of the control unit con-
nector.
• If shorted to negative: no voltage has been detected.
• If the circuit is open: an interruption has been detected.

Troubleshooting

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• If shorted to positive: disconnect the injector connector, set the key to ON and check if there
is voltage on the yellow/red cable: if there is voltage, restore the cable harness; if there is
not, replace the injector.
• If shorted to negative: disconnect the injector connector, set the key to ON and check if there
is continuity between the yellow/red cable and the ground connection: if there is continuity
with the ground connection, restore the cable harness; if there is not continuity, replace the
injector.
• The circuit is open: check the component correct electrical characteristic: if it is not the cor-
rect one, replace the component; if it is correct, check the connector on the component and
the Marelli control unit connector: If not OK, restore; if OK, check continuity between the
cable of PIN 6 control unit connector and PIN 1 of the component and restore the cable
harness.

Coil
Function
It controls the ignition spark plug in order to gen-
erate the fuel ignition spark.
Operation / Operating principle
Inductive discharge system.
Level in electrical circuit diagram:Coils and in-
jectors
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 supply + Vbatt

2. Circuit ground
NAVIGATOR: PARAMETERS
• Left coil ignition advance.
• Right coil ignition advance.
NAVIGATOR: ACTIVATION

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Left coil:
The auxiliary injection relay (No. 12 in the wiring diagram, placed under saddle, second relay starting
from the front; CHECK, however, the identification of the relay with the colour of the cables) is energised
for 5 seconds and the orange/white cable of the coil is closed to ground for 2 ms per second. Disconnect
the 4-way connector of the fuel pump to be able to hear the relay and injector activation. The continuity
of the wiring is necessary for correct activation: no error indications are displayed in case of lack of
activation.

NAVIGATOR: ELECTRICAL ERRORS

Left coil - shorted to positive / open circuit, shorted to negative
Error cause
• If shorted to positive: excessive voltage has been detected at PIN 20 of the control unit
connector.
• If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 20
of the control unit connector

Troubleshooting
• shorted to positive: disconnect the coil connector, set the key to ON, activate the coil with
Navigator and check voltage at connector PIN 2: if there is voltage, restore the cable har-
ness; if voltage = 0, replace the coil
• if the circuit is open, shorted to negative: check the coil connector and the Marelli control
unit connector. If not OK, restore; if everything is OK, check cable continuity between the
two cable terminals. If there is no continuity, restore the cable harness; if there is cable
continuity, with key set to ON, check the cable earth insulation (from coil connector or control
unit connector). If not OK, restore the cable harness.

Right coil:
The auxiliary injection relay (No. 12 in the wiring diagram, placed under saddle, second relay starting
from the front; CHECK, however, the identification of the relay with the colour of the cables) is energised
for 5 seconds and the orange/blue cable of the coil is closed to ground for 2 ms per second. Disconnect
the 4-way connector of the fuel pump to be able to hear the relay and injector activation. The continuity
of the wiring is necessary for correct activation: no error indications are displayed in case of lack of
activation.

Right coil - shorted to positive / open circuit, shorted to negative.

Error cause
• If shorted to positive: excessive voltage has been detected at PIN 14 of the control unit
connector.
• If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 14
of the control unit connector

Troubleshooting

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• shorted to positive: disconnect the coil connector, set the key to ON, activate the coil with
Navigator and check voltage at connector PIN 2: if there is voltage, restore the cable har-
ness; if voltage = 0, replace the coil.
• if the circuit is open, shorted to negative: check the coil connector and the Marelli control
unit connector. If not OK, restore; if everything is OK, check cable continuity between the
two cable terminals. If there is no continuity, restore the cable harness; if there is cable
continuity, with key set to ON, check the cable earth insulation (from coil connector or control
unit connector). If not OK, restore the cable harness.

Engine oil pressure sensor

Function:Indicates the instrument panel if there is
enough oil pressure (0.35 +/- 0.2 bar) (5.1 +/- 2.9
PSI) in the engine.
Operation / Operating principle: normally closed
switch. With oil pressure above 0.35 +/-0.2 bar (5.1
+/- 2.9 PSI), open circuit.
Level in wiring diagram:fuel reserve and oil pres-
sure.
Location:

• sensor: between the two heads, at the

back.
• connector: on the sensor.

Electrical characteristics:

• With engine off: closed circuit (continu-

ity).
• With engine started: open circuit (infin-
ite resistance).

Pin-out: Voltage 12V

Instrument panel
Warning light always off
Troubleshooting
• Check the sensor connector and the instrument panel connector (PIN 17): If not OK, restore.
If OK, check the continuity of the purple cable between the sensor connector and the in-
strument panel connector PIN 11: if not OK, restore the cable harness; if OK, replace the
sensor
Warning light always on
Troubleshooting

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• Disconnect the sensor connector and check the ground insulation of the purple cable: if there
is continuity with the ground connection, restore the cable harness; if earth insulated, replace
the switch. if the error remains, check oil pressure in the engine circuit with a pressure gauge

Neutral sensor
Function
it tell the gear position to the instrument panel: if it is in neutral or in gear.
Operation / Operating principle
for neutral gear, the circuit is closed to ground connection: the instrument panel turns on the neutral
warning light.
Level in wiring diagram:start-up enabling switches
Location:
• sensor: rear / upper section of the gearbox
• connector: on the sensor
Electrical characteristics:
• Gear in neutral: closed circuit (0 V on wire from instrument panel to sensor / switch in con-
tinuity).
• Gearshift: open circuit (12 V on wire from instrument panel to sensor) / open switch, infinite
resistance
Pin-out:
1. Voltage 12V
DIAGNOSIS
NEUTRAL warning light always off: check black-green/brown cable (cable harness side): if it is no OK,
restore cable harness; if it is OK, disconnect the connector and check, with gear in neutral, the continuity
between the ground connection and the terminal on the sensor side: if there is not continuity, replace
sensor (after checking cable harness continuity on the sensor side and correct mechanic position); if
there is continuity, check continuity of the black-brown/green cable between sensor connector and main
injection relay: if there is not continuity, restore the cable harness; if there is continuity, replace instru-
ment panel if the vehicle operation is correct.
NEUTRAL warning light always on: disconnect the terminals from the sensor and check if there is
continuity between the ground connection and the PIN towards the sensor, with gear engaged: if there
is continuity, replace the sensor; if it is earth insulated, it means that the black-brown/green cable from
the sensor PIN to the main injection relay is shorted to ground: restore the cable harness

Clutch lever sensor

Function
It tells the clutch lever position to the control unit.

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Operation / Operating principle

To start-up the engine, pull the clutch with gear in neutral.
Level in wiring diagram:Start-up enabling switches.
Location:
• sensor: under clutch lever
• connector: under the fuel tank
Electrical characteristics:
• Clutch pulled: closed circuit (continuity)
• Clutch released: open circuit (infinite resistance)
Pin-out:
1. Ground connection
2. Voltage 12V
DIAGNOSIS
• Although the clutch lever is operated, the vehicle does not start. Check that if the gear is
engaged, the stand is retracted; if it is OK, check continuity of the brown/green cable be-
tween the sensor connector (cable harness side) and the main injection relay: if still there
is no continuity, restore the cable harness; if there is continuity, disconnect the sensor con-
nector and check, with clutch pulled, if there is continuity between the 2 PIN of the connector
on the sensor side. If there is not continuity, replace sensor; if there is continuity, check
continuity of the purple cable between sensor (cable harness side) and start-up relay; oth-
erwise, restore the cable harness.
• The vehicle starts without pulling the clutch lever: disconnect the terminals from the sensor
and check if the released clutch sensor has continuity between the 2 PINS; if there is con-
tinuity, replace the sensor; if there is not continuity, it means that the purple cable from the
sensor PIN to the start-up relay is shorted to ground.

Side stand sensor

Function
It tells the side stand position to the control unit.
Operation / Operating principle
If the gear is engaged and the side stand is unfolded, and therefore the circuit is open, the control unit
does not enable vehicle start-up or shuts off the engine if it is rotating.
Level in wiring diagram:start-up enabling switches
Location:
• sensor: on side stand supporting plate
• connector: left side, near the starter motor
Electrical characteristics:

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• Side Stand Up: closed circuit (continuity)

• Side Stand Down: open circuit (infinite resistance)

Pin-out:

• Blue (cable harness side): Ground connection

• Green/brown (cable harness side): voltage 12V

DIAGNOSIS

• The vehicle with clutch pulled, gear engaged and side stand retracted does not start (side
stand switch always open): check continuity of the green/brown cable between PIN 2 of
diode 40 (wiring diagram) and the corresponding PIN of the sensor connector on the cable
harness side. If there is not continuity, restore cable harness; if there is continuity, with side
stand retracted, check continuity between the 2 PINS of the sensor. If there is not, replace
the sensor; if there is continuity, check continuity to ground connection of the blue cable on
the connector (cable harness side).
• The vehicle, with clutch operated and gear engaged, starts but with the side stand extended:
disconnect the sensor connector and check that, with side stand extended, there is not
continuity between the 2 PINS. If there is continuity, replace the sensor; if there is not con-
tinuity, disconnect diode 40 and check ground insulation of the green/brown cable between
sensor and diode

Bank angle sensor

Function
it tells the vehicle position to the control unit.
Operation / Operating principle
When the sensor is inverted, the circuit is closed
to ground: when the Marelli control unit detects this
ground, it deactivates the circuit of the fuel pump
and the engine start-up circuit, via the injection re-
lay.
Level in wiring diagram:Start-up enabling
switches.
Location:

• under the saddle, rear section

• connector: near the sensor

Electrical characteristics:

• Sensor in vertical position: open circuit

(resistance: 62 kOhm)

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• Sensor inverted: closed circuit (resist-

ance lower than 0.5 kOhm)

Pin-out:

• Pink/yellow (cable harness side): Volt-

age 12V
• Grey (cable harness side): ground con-
nection

DIAGNOSIS
The vehicle starts, even if the sensor is inverted: disconnect the connector and, with sensor inverted,
check if there is continuity between the two PINS of the sensor: if there is not continuity, replace the
sensor; if there is, check the connector. If it is not OK, restore the cable harness; if it is OK, check ground
connection continuity of the PIN marked by the grey cable on the cable harness side: if there is no
continuity, restore the cable harness; if there is, with key set to ON, check if there is 12V voltage at the
PIN marked by the red/yellow cable on the cable harness side. If there is not, check the PIN 16 of the
Marelli control unit connector.
The vehicle does not start with the sensor in vertical position: disconnect the connector and check if
there is continuity between the two PINS when the sensor is in vertical position: if there is continuity,
replace the sensor; if there is not continuity, it means that, with key set to ON, there is not 12V voltage
to the PIN marked by the pink/yellow cable: restore the cable harness whose pink/yellow cable will be
shorted to ground

Air temperature sensor - instrument panel

Function
It tells the ambient air temperature to the instru-
ment panel.
Operation / Operating principle
NTC type sensor (resistance sensor, inversely
variable with temperature).
Level in wiring diagram:Temperature sensors
Location:

• under instrument panel supporting

bracket
• connector: under the start-up lock

Electrical characteristics:

• Resistance at 0°C: 32.5 kOhm +/- 5%

• Resistance at 25°C: 10.0 kOhm +/- 5%

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Pin-out:

1. Voltage 5V
2. Ground connection

DIAGNOSIS
"---" code that indicates an instrument panel error
Air temperature sensor fault
Error cause

• An instrument panel temperature sensor failure is signalled when it is detected that the
sensor circuit is open or shorted to positive/negative

Troubleshooting

• Check the sensor connector and the instrument panel connector (PIN 12): if it is not OK,
restore; if it is OK, check the continuity of the pink cable between the sensor connector (cable
harness side) and the PIN 12 of the instrument panel connector: if not OK, restore the cable
harness; if OK, check the correct sensor resistance: if it is not OK, replace the sensor; if it
is OK, with key set to ON, check if there is voltage at the sensor connector PIN 1: if there is
no voltage, replace the instrument panel; if there is approximately 12V, restore the cable
harness (there is a short circuit in the battery). If there is 5V voltage, connect a 10 kOhm
resistance to PIN 1 of the sensor connector and to the vehicle ground connection: if, with
key set to ON, the voltage measured upstream the resistance decreases, replace the in-
strument panel. If voltage continues to be approximately 5V, restore the pink cable (there is
a short circuit at + 5V). In case there is a short circuit to ground connection of PIN 12 of the
instrument panel connector: Check the earth insulation of the sensor connector pink cable:
if there is a connection, restore the cable harness; if it is earth insulated, check that sensor
resistance is correct: if not OK, replace the sensor; if it is 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 driver wants to shut off the engine or to disable engine start-up, the switch should be open, i.e.
the Marelli control unit should not detect voltage at PIN 26 of the control unit connector.
Level in electrical circuit diagram:start-up enabling switches.
Location:

• sensor: right light switch

• connector: next to the headstock, right side

Electrical characteristics:

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• STOP position: the circuit is open

• RUN position: closed circuit (continuity)

PIN:
red/grey cable (watching the cable harness):

• voltage 0 V with engine kill in STOP;

• 12 V with engine kill in RUN.

Orange/red cable (cable harness side): always voltage 12 V (with key on)
DIAGNOSIS

• Engine does not start: disconnect the connector and with switch set to RUN, check if there
is continuity between the two grey/light blue and red/green cables (sensor side): if there is
not continuity, replace the sensor; if there is continuity, check the connector. If it is not OK,
restore cable harness; if it is OK, with key set to ON, check that there is voltage on the
orange/red cable (cable harness side); if there is no voltage, restore cable harness; if there
is voltage, check earth insulation of the red/grey cable (cable harness side). If there is con-
tinuity with ground connection, restore the 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 with switch
in STOP, check if there is continuity between the two grey/light blue and red/green cables
(sensor side); if there is continuity, replace the switch; if there is not continuity, it means that,
with KEY ON, the red/grey cable (between switch and main injection relay) and/or the grey/
black cable (between main injection relay and Marelli control unit) are in shorted to positive:
restore the cable harness. If cable harness is OK, replace the Marelli control unit

Connectors

ECU

PIN:

1. Throttle position sensor supply - Power out-

put
2. Lambda probe signal (ground) - Analogue
input
3. Rpm indicator control - Frequency output
4. Cylinder head temperature sensor signal -
Analogue input
5. -
6. Right injector control - Power output

ELE SYS - 80
V7 Racer Electrical system

7. Engine revolution sensor - Frequency input

8. Lambda probe signal (positive) - Analogue
input
9. Diagnosis line (K) - Communication line
10.Diagnosis line (L) - Communication line
11.Throttle position signal - Analogue input
12.Engine revolution sensor - Frequency input
13.Right injector control - Power output
14.Right coil control - Power output
15.Injection telltale light control - Digital output
16.Fall sensor signal - Digital input
17.Control unit supply - Power input
18.Intake air temperature sensor signal - Ana-
logue input
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. Left arrow input
10.Neutral input
11.Oil input
12.Air temperature input

ELE SYS - 81
Electrical system V7 Racer

13.Speed sensor power supply

14.Ground connection
15.K Line
16.n.c.
17.Speed input
18.Engine revs input
19.n.c.
20.Reserve input
21.Key
22.Ground connection
23.Battery
24.Front right arrow output
25.Rear right arrow output
26.Battery

ELE SYS - 82
INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

Engine from vehicle V7 Racer

Vehicle preparation

• Before removing the engine block, re-

move the fuel tank, the battery, the
exhaust pipes, the shock absorbers
and the rear wheel.
• Disconnect the speed sensor connec-
tion and slide off the cable from the
cable harness.

• Remove the swingarm and the bevel

gear pair.

Removing the engine from the vehicle

GEAR SHIFT
pos. Description Type Quantity Torque Notes
1 Screw fastening left hand rider foot- M8x20 2 25 Nm (18.44 lb ft) Loctite 243
rest mounting plate to cradle

ENG VE - 84
V7 Racer Engine from vehicle

pos. Description Type Quantity Torque Notes

2 Preselector lever fixing screw M6x20 1 10 Nm (7.37 lb ft) -
3 Gearbox lever fixing screws M6x20 1 10 Nm (7.37 lb ft) Loctite 243
4 Gearbox control rod fixing nut M6x1 1 10 Nm (7.37 lb ft) -
5 Screw fastening rider footrest mount- M8 1 20 Nm (14.75 lb ft) Loctite 243
ing to plate

• Disconnect the electrical connections

of the generator.

• Remove the revolution sensor but

keep it connected to the cable harness.

• Slide the pin, with the split pin, fixing

the linkage to the clutch to the engine
block and then release the control ca-
ble.

ENG VE - 85
Engine from vehicle V7 Racer

• Remove the injectors lock and slide in-

jectors off there seat on the inlet mani-
folds.

• Disconnect the spark plug cables from

the coils and slide them off the chassis.

ENG VE - 86
V7 Racer Engine from vehicle

• Loosen the clamps on the intake mani-

folds.

• Disconnect the oil breather pipe on the

cylinder heads.

• Remove the connection of the engine

temperature sensor.

• Disconnect the starter motor and the

lambda probe.

ENG VE - 87
Engine from vehicle V7 Racer

• Open the clamp and disconnect the oil

breather pipe of the air filter casing.

• Disconnect the neutral indicator.

• Disconnect the connector of the side

stand safety switch and slide off the
cable harness from the chassis.

ENG VE - 88
V7 Racer Engine from vehicle

• Undo and remove the screw.

• Remove the gear transmission lever.

• Undo and remove the two right footrest

screws, move the rear brake pedal that
is still attached to the tank and to the
calliper.

• Undo the screw fixing the ground eye-

let on the engine block.

• Support the vehicle chassis by means

of a hoister.
• Undo the four Allen head screws fixing
the front arms of the chassis to the en-
gine cradle.

• Remove the upper screws fixing the chassis to the gearbox cover.

ENG VE - 89
Engine from vehicle V7 Racer

• Remove the rod fixing the chassis to

the gearbox .

• Remove the engine: check that during

the removal operation, the throttle
body sleeves slide off the inlet mani-
folds without getting damaged.

• Lower the engine checking that it gets correctly detached from the chassis.

• During this removal operation, discon-

nect the connection of the oil pressure
transmitter.

ENG VE - 90
V7 Racer Engine from vehicle

Installing the engine to the vehicle

FRAME CRADLES
pos. Description Type Quantity Torque Notes
1 Screw fixing stand beam to cradle M10x260 1 50 Nm (36.88 lbf ft) -
2 Screw fixing stand beam to cradle M8 1+1 25 Nm (18.44 lbf ft) -
3 Pin fixing engine/gearbox to chassis M10x250 1 50 Nm (36.88 lbf ft) -
4 Screw fastening cradle to frame M10x65 2 50 Nm (36.88 lbf ft) -

ENG VE - 91
Engine from vehicle V7 Racer

FRAME
pos. Description Type Quantity Torque Notes
1 Screw fixing tank mounting rubber M8x14 2 25 Nm (18.44 lbf ft) -
blocks to frame
2 Cradle front fixing screw M10x30 4 50 Nm (36.88 lbf ft) -
3 Screw fastening gearbox to frame M10x55 2 50 Nm (36.88 lbf ft) -
4 Pin fixing engine/gearbox to chassis M10x205 1 50 Nm (36.88 lbf ft) -
5 Screw fixing exhaust silencer mount- M8x16 4 25 Nm (18.44 lbf ft) Loctite 243
ing to frame
6 Battery supporting plate fixing screw M8x16 4 25 Nm (18.44 lbf ft) -

• Secure the vehicle chassis by fasten-

ing it with a hoister and lift the engine
to place it in its position.
• During this operation, connect again
the oil pressure transmitter connection
and check that the throttle body
sleeves are inserted correctly on the
intake manifolds.

• With the engine in position, fit the rod fixing the chassis to the gearbox, tightening it to the
prescribed torque.

• Tighten to the prescribed torque the

upper screws fixing the chassis to the
gearbox cover.

• Fasten the chassis front arms to the

engine cradle using the four Allen head
screws. Tighten them to the prescribed
torque.

ENG VE - 92
V7 Racer Engine from vehicle

• Fit the screw fixing the ground eyelet

on the engine block.

• Restore the connection of the side

stand safety switch.

• Connect the neutral indicator.

• Insert the oil breather pipe in the air fil-

ter casing and lock it with the corre-
sponding clamp.

ENG VE - 93
Engine from vehicle V7 Racer

• Connect the starter motor and the

lambda probe.

• Restore the connection of the engine

temperature sensor.

• Insert the breather pipes on the cylin-

der heads and lock them with the spe-
cific clamps.

ENG VE - 94
V7 Racer Engine from vehicle

• Tighten the clamps on the intake mani-

folds.

• Insert the injectors in their positions

and fit the locking ring, tightening the
screw to the prescribed torque.

• Connect the spark plug cables on the

ignition coils.

ENG VE - 95
Engine from vehicle V7 Racer

• Place the clutch linkage and insert the

pin on the engine block, locking it with
the corresponding split pin.

• Refit the swingarm and the bevel gear

pair.

ENG VE - 96
V7 Racer Engine from vehicle

• Fit the revolution sensor by tightening

the screws to the prescribed torque.

• Restore the electrical connections of

the generator.

• Restore the connection of the vehicle

speed sensor.

ENG VE - 97
INDEX OF TOPICS

ENGINE ENG
V7 Racer Engine

TO CONSULT THE CHAPTER ABOUT THE ENGINE AND ITS COMPONENTS PLEASE REFER TO
THE APPROPRIATE MANUAL:
"MSS Engine V750 IE"

ENG - 99
INDEX OF TOPICS

POWER SUPPLY P SUPP

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 - 101
Power supply V7 Racer

Diagram

Key:

1. Control unit position

2. Ignition switch
3. Battery
4. Fuel pump
5. Coils
6. Instrument panel
7. Air temperature sensor
8. Throttle valve position sensor
9. Injectors
10.Crankshaft position sensor
11.Engine temperature sensor
12.Lambda Probe

P SUPP - 102
V7 Racer Power supply

13.Fall sensor
14.Side stand

Cylinders synchronisation

• With engine off, connect the Navigator

tool to the diagnosis connector and to
the vehicle battery.

• Turn on the scanner.

• Screw the joints connecting the vacu-
ometer pipes on the intake pipe holes.
• Connect the vacuometer pipes to the
relative joints.

• Place the Navigator on the adjustment screen page.

• Make sure the throttle valve is fully in.
• Autodetect the throttle position.

• Turn the key to "OFF" and leave it for at least 30 seconds.

DO NOT TOUCH THE THROTTLE ABUTMENT SCREW OR THE THROTTLE BODY MUST BE RE-
PLACED. CHECK THAT THE THROTTLE RETURN CABLE IS NOT TAUT.
• Start the engine.
• Take the engine to the prescribed tem-
perature: 50 °C (122 °F).
• Completely close the two by-pass
screws on the throttle bodies.

P SUPP - 103
Power supply V7 Racer

• Take the engine to an out-of-idle

speed: 2000 - 3000 rpm.
• Check cylinder compensation on the
vacuometer.

• To correct compensation use the set

screw of the control rod of the throttle
bodies, on the left side of the vehicle,
until cylinders are compensated.

Now, it is necessary to adjust idle speed:

• Take the engine to the prescribed temperature: 70 - 80°C (158 - 176 °F).
• Operating the by-pass screws, adjust idle: 1100 ± 50 rpm.

Co rate adjustment

It is not possible to adjust CO (time of injectors opening) but just resetting the self-adjustable parameters
in case the throttle body is replaced because it is worn.

P SUPP - 104
V7 Racer Power supply

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
Mapping -

PARAMETERS screen page

This screen page shows the parameters meas-

ured by the several sensors (engine revs, engine
temperature, etc.) or values set by the control unit
(injection time, ignition advance, etc.)

ENGINE PARAMETER READING SCREEN PAGE

Specification Desc./Quantity
Throttle Value corresponding to the throttle when closed (approximate
value between 4.5 and 4.9°) (left throttle supported by the end
of stroke screw). If a different value is read, it is necessary to
activate the parameter "Throttle positioner autodetection" and
obtain this value.
TPS Trimmer Supplementary parameter related to throttle keying in calibra-
tion.
Precise throttle position Throttle opening angle in degrees: once the throttle position
self-learning is carried out, it falls within the following value
range: 3.1° ± 0.4°.
Lambda Probe 300 - 3000 mV (approximate values).
Signal when energised that the control unit receives from the
lambda probe: inversely proportional to the presence of oxy-
gen.
Lambda integrator When the control unit uses the lambda probe signal (see the
'Lambda' parameter on the 'Device status' display) this value
should be close to 0%
Partial load self-adjustment Supplementary correction factor for the injection time, in out-
of-idle condition.
Idle check self-adjustment Supplementary correction factor for the injection time, in idle
condition.
Rich multiplicative correction Multiplicative correction factor for the injection time.
Not synchronised timing of a tooth Number of engine timing steps during which the revolution tim-
ing sensor has lost the signal of a tooth.

P SUPP - 105
Power supply V7 Racer

Specification Desc./Quantity
Higher not synchronised timing of a tooth Number of engine timing steps during which the revolution tim-
ing sensor has lost the signal of more than one tooth.
Engine rpm Engine revolutions per minute: the minimum value is set by the
control unit cannot be adjusted
Injection time - ms
Ignition advance -°
Atmospheric pressure 1015 mPa (approximate values)
The sensor is inside the instrument panel
Air temperature °C
Temperature of the air taken in by the engine, measured by the
sensor in the filter casing. This is not the temperature indicated
by the instrument panel
Engine temperature °C
Battery voltage V

STATUS screen page

This screen page shows the status (usually ON/

OFF) of the vehicle devices or the operation con-
dition of some vehicle systems (for example, lamb-
da probe functioning status).

DEVICE STATUS
Specification Desc./Quantity
Engine status ON/run/power-latch/stopped
operation conditions
RPM sensor Synchronised / Not synchronised.
Throttle position Released / pressed
indicates if the throttle potentiometer is open or closed
Lambda Open loop / Closed loop
Indicates if the control unit is using (CLOSED) the lambda
probe signal to keep the stoichiometric combustion. At idle
CLOSED only if: Air T over 20°C (68°F) and engine T over 30°
C (86°F) and engine on for at least 2-3 minutes

ACTIVATION screen page

This screen page is used to delete errors in the

control unit memory and to activate some systems
controlled by the control unit.

P SUPP - 106
V7 Racer Power supply

DEVICES ACTIVATION
Specification Desc./Quantity
Error clearing By pressing the 'enter' button, the stored errors (MEM) become
part of the historical data (STO). In the next connection be-
tween the Navigator and the control unit, the historical errors
(STO) are no longer shown
Fuel pump Operation for 30''
Left coil operation for 2.5 m, 5 times
Right coil operation for 2.5 m, 5 times
Rpm indicator Control at 125 Hz (3750 rpm) for 2 seconds.
Left injector Operation for 2 ms per second for 5 times.
Right injector Operation for 2 ms per second for 5 times.

ERRORS screen page

This screen page shows potential errors detected

in the vehicle (ATT) or stored in the control unit
(MEM) and it allows to check error clearing (STO).

ERRORS DISPLAY
Specification Desc./Quantity
Engine temperature Possible short circuit in the earth lead, battery or open circuit.
Left coil Possible short circuit in the earth lead, battery or open circuit.
If both coils do not work, the engine does not work.
Right coil Possible short circuit in the earth lead, battery or open circuit.
If both coils do not work, the engine does not work.
Left injector Possible short circuit in the earth lead, battery or open circuit.
If both injectors do not work, the engine does not work
Right injector Possible short circuit in the earth lead, battery or open circuit.
If both injectors do not work, the engine does not work
Lambda Probe Possible short circuit in the earth lead, battery or open circuit.
Air temperature Possible short circuit in the earth lead, battery or open circuit.
Throttle Possible short circuit in the earth lead, battery or open circuit.
Pressure Possible short circuit in the earth lead, battery or open circuit.
Battery voltage Battery voltage detected is too low (7V) or too high (16V) for a
certain period
Fuel pump relay Possible short circuit in the earth lead, battery or open circuit:
the engine does not start.
Self-adjustable parameters -
RAM memory Possible internal control unit error. Also check the control unit
supply and earth connections
ROM memory Possible internal control unit error. Also check the control unit
supply and earth connections
Checksum EPROM Possible internal control unit error. Also check the control unit
supply and earth connections
Microprocessor Possible internal control unit error. Also check the control unit
supply and earth connections
RPM sensor -

P SUPP - 107
Power supply V7 Racer

SETTINGS screen page

This screen page is used to adjust some control

unit parameters.

ADJUSTABLE PARAMETERS
Specification Desc./Quantity
Throttle positioner autodetection Allows the control unit to detect the closed throttle position: just
press the enter button
Self-adjustable parameters reset Reset the self-adjustable parameters of the lambda check
when important parts of engine (valves, cylinder, camshaft),
exhaust system, control unit, supply system and lambda probe
should be replaced.
The three self-adjustable correction factors of the lambda
check related to the injection time are reset electronically.

P SUPP - 108
INDEX OF TOPICS

SUSPENSIONS SUSP
Suspensions V7 Racer

Front

FRONT WHEEL
pos. Description Type Quantity Torque Notes
1 Front wheel axle M18x1.5 1 80 Nm (59.00 lbf ft) -
2 Front brake disc fixing screw M8x20 6 25 Nm (18.44 lbf ft) Loctite 243

Removing the front wheel

• Place the vehicle on a stable support

so that the front wheel does not touch
the ground.
• Remove the brake calliper without dis-
connecting the oil pipes

• Remove the front wheel.

SUSP - 110
V7 Racer Suspensions

Handlebar

HANDLEBAR AND CONTROLS

Pos. Description Type Quantity Torque Notes
1 Switch fastener screw M5 1+1 1.5 Nm (1.11 lb ft) Tighten using a 1-2-1 se-
quence
2 Semi-handlebar fixing screw M6x25 4 10 Nm (7.37 lb ft) Tighten using a 1-2-1 se-
quence
3 Counterweight fixing screw M6 2 10 Nm (7.37 lb ft) Loctite 243
4 Screw fastening the clutch control U-bolt to M6x25 2 10 Nm (7.37 lb ft) Tighten using a 1-2-1 se-
the semi-handlebar quence

SUSP - 111
Suspensions V7 Racer

Front fork

FRONT SUSPENSION - STEERING

pos. Description Type Quantity Torque Notes
1 Stanchion cap - 2 50 Nm (36.88 lbf ft) -
2 Screw fixing wheel axle to right fork leg M6x30 2 10 Nm (7.37 lbf ft) Tighten using a 1-2-1 se-
quence
3 Screw fixing stanchions to upper and lower M10x40 4 50 Nm (36.88 lbf ft) -
plate
4 Headstock ring nut M25x1 1 7 Nm (5.16 lbf ft) The fork must fall to one
side by itself

SUSP - 112
V7 Racer Suspensions

pos. Description Type Quantity Torque Notes

5 Headstock bushing M23x1 1 50 Nm (36.88 lbf ft) -

Diagram

Key:

1. Screw
2. Washer
3. Screw
4. Complete left sleeve
5. Upper bushing
6. Washer
7. Sealing ring
8. Snap ring
9. Dust guard
10.Stem
11.Lower bushing
12.Buffer
13.Counter spring
14.Complete pumping member
15.Spring
16.Pipe
17.Complete cap

SUSP - 113
Suspensions V7 Racer

18.Screw
19.Base with headstock
20.Ring nut
21.Fork upper plate
22.Washer
23.Nut
24.Rubber ring
25.Spacer
26.Cap
27.Nut
28.Ring
29.Complete right sleeve
30.Lower U-bolt
31.Upper U-bolt
32.Screw
33.Screw
34.O-ring
35.Stem protection
36.Chrome-plated cap
37.Gasket kit
38.Oil seal kit

Removing the fork legs

NOTE

PAY ATTENTION TO THE TYPE OF FORK FITTED DURING

REMOVAL AND FITTING. TWO DIFFERENT SUPPLIES
CAN BE FOUND ON THIS MOTORCYLCE, MARZOCCHI OR
KAIFA. TO DISTINGUISH BETWEEN THEM IT IS NECES-
SARY TO PROCEED WITH THE REMOVAL. THE MARZOC-
CHI FORK, UNLIKE THE KAIFA ONE IS EQUIPPED WITH A
WASHER ABOVE THE PRELOAD TUBE AND A SHIM
HOUSED BELOW.

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.

SUSP - 114
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.

• Slide off the stem downwards by turning it slightly first in one direction then to the opposite
direction.

SUSP - 115
Suspensions V7 Racer

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.

• Unscrew the upper closing cap. Pay

attention to the possible thrust that the
spring can cause to the loosened cap.

KAIFA FORK PROCEDURE

• 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.

MARZOCCHI FORK PROCEDURE

• Be careful not to damage the O-Ring

during extraction.
• Remove the washer.
• Press the bearing tube inside the
wheel holder fork leg.
• Remove the preload tube and the
spring.

SUSP - 116
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.

• Carefully check each part of the stan-

chion and make sure that there are no
damaged elements.
• If there are no damaged or worn ele-
ments, 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.

SUSP - 117
Suspensions V7 Racer

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.
CAUTION
BE CAREFUL NOT TO DAMAGE THE FORK LEG RIM AND
THE DUST SCRAPER.

• Slide the dust scraper off and upwards.

• Remove the locking ring inside the fork

leg using a thin screwdriver.
CAUTION
BE CAREFUL NOT TO DAMAGE THE FORK LEG RIM.

SUSP - 118
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. 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 and replace it if damaged or
worn.
• Slide off the pumping member unit
from the holding tube; if it is damaged,
replace the counter spring and the ring.

Reassembling the fork

CAUTION
ALL COMPONENTS MUST BE CAREFULLY WASHED AND DRIED WITH COMPRESSED AIR BE-
FORE REFITTING.
• Carry out any necessary service oper-
ation.
• Insert the pumping member unit with
the counter spring and the ring in the
bearing tube.

SUSP - 119
Suspensions V7 Racer

• 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.

• Insert the bearing tube in the wheel

holder and push it until it stops.

SUSP - 120
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
sealing ring in the fork leg until it stops.

• Fit the locking ring.

• Fit the dust scraper.

• Pour oil into the bearing tube so that it
also fills the internal grooves of the
pumping member rod.
• Pump with the bearing tube, making
sure the oil has completely filled the
pumping member rod.
• Introduce the spring and the preload
tube.
• Place the cap on the bearing tube, tak-
ing care not to damage the O-ring.
Then, tighten the cap to the prescribed
torque.

SUSP - 121
Suspensions V7 Racer

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.
• 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
MUST BE THE SAME IN BOTH STANCHIONS.

Characteristic
Marzocchi Oil level (from the sleeve edge, with-
out the spring and with stanchion to end of
stroke)
150 mm (5.9 in)
Kaifa Oil level (from the sleeve edge, without
the spring and with stanchion to end of stroke)
120 +/- 1.5 mm (4.72 +/- 0.06 in)

• Introduce the spring and the preload

tube.

SUSP - 122
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.

SUSP - 123
Suspensions V7 Racer

• Tighten the screws to the prescribed

torque.

SUSP - 124
V7 Racer Suspensions

Steering bearing

FRONT SUSPENSION - STEERING

pos. Description Type Quantity Torque Notes
1 Stanchion cap - 2 50 Nm (36.88 lbf ft) -
2 Screw fixing wheel axle to right fork leg M6x30 2 10 Nm (7.37 lbf ft) Tighten using a 1-2-1 se-
quence
3 Screw fixing stanchions to upper and lower M10x40 4 50 Nm (36.88 lbf ft) -
plate
4 Headstock ring nut M25x1 1 7 Nm (5.16 lbf ft) The fork must fall to one
side by itself

SUSP - 125
Suspensions V7 Racer

pos. Description Type Quantity Torque Notes

5 Headstock bushing M23x1 1 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-
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.

• Remove the upper plate from the front

fork.

SUSP - 126
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.
• Fit the handlebar.
• Fit the instrument panel.

Rear

SUSP - 127
Suspensions V7 Racer

Shock absorbers

REAR SUSPENSION
pos. Description Type Quantity Torque Notes
1 Upper screw fastening shock absorber to M6x35 2 10 Nm (7.37 lbf ft) Loctite 243
frame
2 Lower pin fastening left shock absorber to M10x1.5 1 35 Nm (25.81 lbf ft)
swingarm
3 Stud bolt fixing right shock absorber to rear M12x1.5 1 35 Nm (25.81 lbf ft) -
box
4 Screw fastening right shock absorber to stud M6x16 1 10 Nm (7.37 lbf ft) Loctite 243
bolt

Removing

• Undo and remove the upper screw.

SUSP - 128
V7 Racer Suspensions

• Undo and remove the lower screw.

SUSP - 129
INDEX OF TOPICS

CHASSIS CHAS
V7 Racer Chassis

Swinging arm

REAR TRANSMISSION - SWINGARM

pos. Description Type Quantity Torque Notes
1 Swingarm clamp retaining screw M10x45 1 30 Nm (22.13 lbf ft) -
2 Pin fixing the rear calliper holding M16x1 1 25 Nm (18.44 lbf ft) -
plate to swingarm
3 Nut fixing gearcase to swingarm M8 4 25 Nm (18.44 lbf 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 lbf ft) Hold the pin

CHAS - 131
Chassis V7 Racer

REAR WHEEL
pos. Description Type Quantity Torque Notes
1 Rear wheel axle nut M16x1.5 1 120 Nm (88.51 lb ft) -
2 Rear brake disc fixing screw M8x25 6 25 Nm (18.44 lb ft) Loctite 243

Removing

• Remove the left silencer.

CHAS - 132
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.

• Unscrew and remove the nut and col-

lect the washer.

CHAS - 133
Chassis V7 Racer

• 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 - 134
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.

Checking

• Check that the universal joint is not damaged, the gear teeth inserting in the sleeve grooves
and the grooves on the joint are not deformed or damaged; otherwise, replace the joint.
• 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 it.
• Check that the sealing ring (Seeger) is still flexible and is not deformed.
• Check that the sleeve outer toothing and internal grooves are not damaged.

CHAS - 135
Chassis V7 Racer

Installing

• Insert the swingarm on the gearbox

cover.
• Tighten thoroughly the pin on the left
side until the shimming washer on the
right side rests on the bearing fitted on
the gearbox cover.

• Tighten thoroughly the pin on the right

side, without locking it.
• Operate the swingarm and make sure
it oscillates freely without clearance.

• Screw in the lock nuts on the pins, lock-

ing them thoroughly.

• Screw the clamp.

CHAS - 136
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.

• Slide off the spring.
• Slide off the sealing ring.
• Slide off the base.

CHAS - 137
Chassis V7 Racer

• 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

(19907100) of the bevel gear pair.

• Insert the grooved shank of the pinion

on the tool and unscrew the nut.

CHAS - 138
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

case.
• Slide off the O-ring.
• Slide off the spacer.
• Slide off the two shim washers.

CHAS - 139
Chassis V7 Racer

• 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
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.

CHAS - 140
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

the pinion using the suitable punch
(19926200).

• Fit both shim washers on the pinion.

• Fit the spacer on the pinion.
• Fit the O-ring.

CHAS - 141
Chassis V7 Racer

• 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

on the tool (19907100) and tighten the
nut.

Smontaggio gruppo scatola

CHAS - 142
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.
• 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.

CHAS - 143
Chassis V7 Racer

• 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.

CHAS - 144
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-

er.

Controllo

• Check that the drilled bolt tongues, where the anti-vibration rubbers operate, are not spoiled;
that the surfaces of: the sealing ring; the bearing on the cover, the external ring of the bearing
on the housing; the groove for the circlip on the drilled bolt are not worn, deformed or spoiled;
otherwise, replace them.
• Check that the sealing ring on the housing is not shattered or is still flexible; otherwise,
replace it.
• That the needle bearing on the housing does not have flattened or worn rollers; otherwise,
replace it.
• Check efficiency of every component and that the coupling surfaces of the housing and cover
are not scored or distorted.

Accoppiamento pignone corona

CHAS - 145
Chassis V7 Racer

For coupling, proceed as follows:

• Provisionally lock the complete pinion

case on the housing with two nuts and
appropriate spacers.
• Fit the corresponding tool on the crown
(19928800).

• Insert the tool on the bearing cage in

the housing.

• Check alignment between pinion teeth

and the crown teeth.
• If alignment is not regular, properly
vary the thickness of the ring between
the pinion and the tapered bearing.
• Also check the contact area between
the pinion teeth and the crown teeth,
proceeding as follows:

• Apply suitable colours available in the

market on the pinion teeth.

CHAS - 146
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.
• Turn the pinion in the riding direction,
with the crown braked so that the rota-
tion is carried out under load, and
leaves a contact mark on the pinion
surface.

• If the contact is regular, the mark on the

pinion teeth will be like this (the pinion
is seen from the crankshaft side

• If the contact is like this, the crown is

too near the pinion rotation axis: de-
tach the crown by increasing spacer
thickness.

CHAS - 147
Chassis V7 Racer

• 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

• If the contact is like this, the crown is

too far from the pinion rotation axis: ap-
proach the crown by reducing spacer
thickness.

Montaggio gruppo scatola

• Fit the washer on the gearcase.

CHAS - 148
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).

• Fit the bearing on the cover using the

suitable punch.

CHAS - 149
Chassis V7 Racer

• Fit the internal ring of the needle bear-

ing on the drilled bolt using the suitable
punch (19927900).
• Insert the sealing ring in the drilled bolt.

• Fit the drilled bolt on the cover.

• Fit the crown.

• Fit the plates and tighten the screws.

CHAS - 150
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.

• Fit the braking disc on the drilled bolt

by locking the screws with the washers
using a torque wrench.

CHAS - 151
Chassis V7 Racer

• 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).

Installing

• Insert the sleeve and base on the bevel

pinion of the gearcase.

CHAS - 152
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

EXHAUST SYSTEM
Pos. Description Type Quantity Torque Notes
1 Exhaust pipe fixing nut to the engine M6 4 10 Nm (7.37 lb ft) -

CHAS - 153
Chassis V7 Racer

Pos. Description Type Quantity Torque Notes

2 Exhaust pipe fixing clamp screw to M6 1+1 10 Nm (7.37 lb ft) -
the compensator
3 Compensator fixing clamp screw to M6 2 10 Nm (7.37 lb ft) -
the silencer
4 Lambda probe on compensator M18x1.5 1 38 Nm (28.03 lb ft) -
5 Nut fastening silencer to mounting M8 4 25 Nm (18.44 lb ft) -
plate
6 Heat shield fixing screw M6x12 6 10 Nm (7.37 lb ft) Loctite 270
7 Screw fixing silencer mounting plate M8x40 2 25 Nm (18.44 lb ft) -
to frame

Key:

1. Right exhaust pipe

2. Left exhaust pipe
3. Expansion chamber
4. Left silencer clamp
5. Gasket
6. Spacer
7. Ring nut
8. Washer
9. Nut
10.Left silencer
11.Right silencer
12.Clamp
13.Right plate
14.Left plate

CHAS - 154
V7 Racer Chassis

15.Right silencer clamp

16.Muffler rubber ring
17.TCEI screw
18.Silencer fixing bushing
19.Nut
20.Clip
21.Lambda Probe
22.Spacer
23.Cap
24.Gasket
25.Protection
26.U-bolt
27.TBEI screw
28.Bushing
29.Insulating washer

Removing the tail pipe

The engine and the exhaust system components get very hot and remain in this condition for a certain
time interval after the engine has been 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.

• Loosen the clamp between the ex-

haust end and the catalytic converter.
• Unscrew and remove the muffler fixing
nut and collect the screw and the bush-
ing.
• Remove the exhaust end.

CHAS - 155
Chassis V7 Racer

Removing the lambda sensor

• Disconnect the lambda probe connec-

tor.

• Unscrew and remove the lambda sen-

sor.

CHAS - 156
INDEX OF TOPICS

BRAKING SYSTEM BRAK SYS

Braking system V7 Racer

Rear brake calliper

REAR BRAKE SYSTEM

pos. Description Type Quantity Torque Notes
1 Rear brake calliper fixing screw M8x30 2 25 Nm (18.44 lb ft) -
2 Drilled screw for brake pipe on cal- - 1 25 Nm (18.44 lb ft) -
liper

1. Rear brake calliper

BRAK SYS - 158

V7 Racer Braking system

2. Plate-torque
3. Brake calliper mounting plate
4. Bushing
5. Spacer
6. Rubber rear brake pipe / Braid rear brake pipe
7. Hydraulic switch
8. Gasket
9. TE Flanged screw
10. Washer 8.4x15
11. Pins + Calliper springs
12. Air bleed
13. M8 Flanged self-locking nut
14. Clamp
15. Stud bolt
16. Ring
17. Clamp
18. Screw
19. Nut M4x0.7
20. Oil pipe screw
21. 6.4x12x1.2 washer
22. M6 Flanged self-locking nut
23. Air bleed cap

Removal

With a centre stand lift the motorcycle and remove the rear wheel

Remove the left exhaust end

Remove the two calliper fixing screws

BRAK SYS - 159

Braking system V7 Racer

Remove the calliper

Installing

Fit the rear brake calliper correctly

Fit the brake calliper fixing screws by tighten them

to the prescribed torque making sure to insert the
washers.

BRAK SYS - 160

V7 Racer Braking system

Front brake calliper

FRONT BRAKE SYSTEM

pos. Description Type Quantity Torque Notes
1 Screw fastening the brake pump U-bolt to the M6x25 2 10 Nm (7.37 lb ft) -
semi-handlebar
2 Front brake calliper fixing screw M10x30 2 50 Nm (36.88 lb ft) -
3 Drilled screw for brake fluid pipe on pump and - 2 25 Nm (18.44 lb ft) -
calliper

BRAK SYS - 161

Braking system V7 Racer

1. Front brake pump

2. Brake pipe
3. M6x12 TE flanged screw
4. TBEI M4x12 screw
5. Stop switch
6. Pump cover
7. U-bolt
8. Lever pin
9. Brake lever
10. Bleeding+hood
11. Pins + Calliper springs
12. Spring
13. Left front brake calliper black
14. Gasket
15. Oil pipe screw
16. TCEI M10x1.25 screw
17 Pads-torque
18. 10.25X20X4 spacer
19. 4.3x8x1.5 washer
20. 6.4x12x1.2 washer

Removal

Place the front brake calliper (3)

Make sure to insert the spacers (2) between the
brake calliper and the fork

BRAK SYS - 162

V7 Racer Braking system

Place the fixing screws (1) of the brake calliper and

tighten them to the prescribed torque.

Remove the fixing screws (1), making sure to col-

lect the spacers (2)

Remove the front brake calliper (3)

Rear brake disc

Removal

• Remove the rear wheel.

BRAK SYS - 163

Braking system V7 Racer

• Unscrew and remove the six brake disc

screws (1).
• Remove the brake disc (2).

UPON REFITTING, APPLY LOCTITE 243 ON THE THREAD

OF THE BRAKE DISC SCREWS (1).
CAUTION
UPON 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.
• The following operations are to be car-
ried out with brake disc fitted on the
wheel.
• Check the disc for wear by measuring
the minimum thickness with a micro-
meter in different points. If the mini-
mum thickness, even in a single point
of the disc, is less than the minimum
value, replace the disc.

Disc thickness minimum value: 4.5 mm (0.18

in)

Front brake disc

Removal

• Remove the front wheel

BRAK SYS - 164

V7 Racer Braking system

• Unscrew and remove the six brake disc

screws (1).
• Remove the brake disc (2).

UPON REFITTING, APPLY LOCTITE 243 ON THE THREAD

OF THE BRAKE DISC SCREWS (1).
CAUTION
UPON REFITTING, SCREW ALL THE SCREWS (1) MAN-
UALLY AND TIGHTEN THEM OPERATING DIAGONALLY
FOLLOWING THIS SEQUENCE: A-B-C-D-E-F.

See also
Removing the
front wheel

Disc Inspection
CAUTION
THE FRONT BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE
SPECIFICATIONS OF THE SYSTEM.

BRAK SYS - 165

Braking system V7 Racer

• The following operations must be car-

ried out with the brake discs fitted on
the wheel; they refer to a single disc,
but are valid for both.
• Check the disc for wear by measuring
the minimum thickness with a micro-
meter in different points. If the mini-
mum thickness, 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 front brake calliper

Remove the Seeger locking the retaining pins of
the brake pads

Remove the brake pad retaining pins

BRAK SYS - 166

V7 Racer Braking system

Collect the protection plate.

Remove the brake pads

Installing

Install the brake pads

Install the protection plate making sure to direct the

arrow, that must be pointed upwards.

BRAK SYS - 167

Braking system V7 Racer

Insert the locking pins of the pads making sure to

also lock the protection plate.

Lock the pins with a seeger ring.

Rear brake pads

Removal

Remove the rear brake calliper

Remove the screws locking the brake pads

BRAK SYS - 168

V7 Racer Braking system

Remove the brake pads

Installing

Install the brake pads

Place and tighten the fixing screws of the brake

pads to the prescribed torque

Bleeding the braking system

Front

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 NECESSARY, AFTER
REFITTING BRAKES AND RESTORING THE BRAKING SYSTEM TO THE REGULAR USE CON-
DITIONS, THAT THE HYDRAULIC CIRCUIT BE AIR PURGED.
NOTE

BRAK SYS - 169

Braking system V7 Racer

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 traditional way or using specific tools such as vacuum
pumps or similar.
In the following is shown the "traditional" bleeding procedure.

• Remove the rubber protection cover

from the bleed valve.
• Insert the transparent plastic pipe in
the front brake calliper bleed valve and
slide the other end of this pipe in a con-
tainer to collect the fluid.
• Remove the front brake oil reservoir
cap.
• 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.
• Repeat the procedure for both callip-
ers.

• Screw the bleeding valve and remove the pipe.

• Top-up the reservoir until the correct brake fluid level is obtained.
• Refit and block the front brake 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 NECESSARY, AFTER
REFITTING 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.

BRAK SYS - 170

V7 Racer Braking system

• Remove the rubber protection cover

from the bleed valve.
• Insert the transparent plastic pipe in
the rear brake calliper bleed valve and
insert the other end of this pipe into a
container to collect the fluid.
• Remove the rear brake oil reservoir
cap.
• 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 protection cover.

Front brake pump

BRAK SYS - 171

Braking system V7 Racer

FRONT BRAKE SYSTEM

pos. Description Type Quantity Torque Notes
1 Screw fastening the brake pump U-bolt to the M6x25 2 10 Nm (7.37 lb ft) -
semi-handlebar
2 Front brake calliper fixing screw M10x30 2 50 Nm (36.88 lb ft) -
3 Drilled screw for brake fluid pipe on pump and - 2 25 Nm (18.44 lb ft) -
calliper

Removal

Drain off the front brake system.

Remove the two brake calliper fixing screws

Disconnect the brake switch connectors.

Remove the brake pump.

BRAK SYS - 172

V7 Racer Braking system

Installing

Connect the front brake pipe fitting

Connect the brake switch connectors

Place the calliper correctly and fix it with the spe-

cial screws to the prescribed tightening torque

Fill up the brake system with the relative bleeding procedure to avoid air bubbles in the system.

Rear brake pump

BRAK SYS - 173

Braking system V7 Racer

REAR BRAKE SYSTEM

pos. Description Type Quantity Torque Notes
1 Rear brake calliper fixing screw M8x30 2 25 Nm (18.44 lb ft) -
2 Drilled screw for brake pipe on cal- - 1 25 Nm (18.44 lb ft) -
liper

(V7 RACER)

RIDER FOOTREST / GEAR SHIFT LEVER

pos. Description Type Quantity Torque Notes
1 Screw fastening left hand rider foot- M8x20 2 25 Nm (18.44 lb ft) Loctite 243
rest mounting plate to cradle
2 Preselector lever fixing screw M6x20 1 10 Nm (7.37 lb ft) -
3 Gearbox lever fixing screws M6x20 1 10 Nm (7.37 lb ft) Loctite 243
4 Gearbox control rod fixing nut M6x1 1 10 Nm (7.37 lb ft) -
5 Screw fastening rider footrest mount- M8 1 20 Nm (14.75 lb ft) Loctite 243
ing to plate

BRAK SYS - 174

V7 Racer Braking system

Rimozione

Remove the screws fixing the protection plate,

making sure to recover the spacer washers

Take the pump from the brake pump shaft

BRAK SYS - 175

Braking system V7 Racer

Remove the brake pipe by acting on the fitting and

empty the system to be able to remove the com-
plete pump.

Installazione

Connect the rear pump brake pipe fitting and tight-

en it to the prescribed torque

Insert the brake pump in the shaft

Place the pump cover and insert the special

screws of the spacer, that must be applied be-
tween the protection and the brake pump.

BRAK SYS - 176

INDEX OF TOPICS

BODYWORK BODYW
Bodywork V7 Racer

BODYWORK - FRONT SECTION

pos. Description Type Quantity Torque Notes
1 Screw fastening stabiliser plate to fork M8x40 4 15 Nm (11.06 lbf ft) Loctite 243
2 Screw fastening mudguard to stabiliser M6x11 4 10 Nm (7.37 lbf ft) Loctite 243
plate
3 Top fairing fixing screw M6 2 10 Nm (7.37 lbf ft)

BODYW - 178
V7 Racer Bodywork

REAR SECTION BODYWORK - LICENSE PLATE MOUNTING

pos. Description Type Quantity Torque Notes
1 Screw fastening retroreflector mounting to license M5x10 2 4 Nm (2.95 lbf ft) -
plate mounting
2 Nut fixing retroreflector to mounting M5 1 4 Nm (2.95 lbf ft) -

Fuel tank

FUEL TANK
pos. Description Type Quantity Torque Notes
1 Rear tank fixing screw M8x45 1 25 Nm (18.44 lb ft) -
2 Screw fastening cap flange to tank M5x12 2+3 4 Nm (2.95 lb ft) -

• Remove the screws that fix the horns.

BODYW - 179
Bodywork V7 Racer

• Unscrew and remove the rear screw.

• Disconnect the connector.

• Disconnect the fuel pipe.

• Remove the fuel breather pipe.

• Remove the fuel tank by sliding it off and back.

BODYW - 180
INDEX OF TOPICS

PRE-DELIVERY PRE DE
Pre-delivery V7 Racer

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:
front and rear suspension unit
front and rear brake calliper retainer unit
front and rear wheel unit
engine - chassis retainers
steering assembly
- Plastic parts fixing screws

Electrical system

- Main switch
- Headlamps: high beam lights, low beam lights, tail lights (front and rear) and their warning lights
- Headlight adjustment according to regulations in force
- Front and rear stop light switches and their bulbs
- Turn indicators and their warning lights
- Instrument panel lights
- Instrument panel: fuel and temperature indicator (if present)
- Instrument panel warning lights
- Horn
- Electric starter
- Engine stop via emergency stop switch and side stand
- Helmet compartment electrical opening switch (if present)

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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.
CAUTION

TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.

INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE
IT IS FIRST USED SHORTENS BATTERY LIFE.
CAUTION

UPON INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG-
ATIVE ONE, AND PERFORM THE REVERSE OPERATION UPON REMOVAL.
WARNING

THE BATTERY ELECTROLYTE IS POISONOUS AS IT MAY CAUSE SERIOUS BURNS. IT CON-

TAINS SULPHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING.
IF IT ACCIDENTALLY COMES INTO CONTACT WITH YOUR EYES OR SKIN, WASH WITH ABUN-
DANT WATER FOR APPROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION.
IF ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR
VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION.
BATTERIES PRODUCE EXPLOSIVE GASES; KEEP CLEAR OF NAKED FLAMES, SPARKS OR
CIGARETTES. VENTILATE THE AREA WHEN RECHARGING INDOORS. ALWAYS WEAR EYE
PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES.
KEEP OUT OF THE REACH OF CHILDREN.
CAUTION

NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING
A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE
A FIRE.

Levels check
- Hydraulic braking system fluid level
- Clutch system fluid level (if present)
- Gearbox oil level (if present)
- Transmission oil level (if present)
- Engine coolant level (if present)
- Engine oil level
- Mixer oil level (if present)

Road test
- Cold start
- Instrument panel operation

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- Response to throttle control

- Stability when accelerating and braking
- Front and rear brake efficiency
- Front and rear suspension efficiency
- Abnormal noise

Static test

Static check after test drive:

- Restarting when warmed up
- Starter operation (if present)
- Minimum holding (turning the handlebar)
- Uniform turning of the steering
- Possible leaks
- Radiator electric fan operation (if present)

Functional inspection

- 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 RECOMMENDED INFLATION PRESSURES AS TYRES MAY BURST.

CAUTION

CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.

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Specific operations for the vehicle

TWO SEATER VERSION

pos. Description Type Quantity Torque Notes
1 Passenger handgrip front fixing M6 2 10 Nm (7.37 lbf ft) -
screw
2 Passenger handgrip rear fixing nut M8 2 25 Nm (18.44 lbf ft) -
3 Passenger footrest mounting bracket M8x16 4 25 Nm (18.44 lbf ft) Loctite 243
fixing screw
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.

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• 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.

• Fit the countersunk 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.

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V7 Racer Pre-delivery

• Lock the bolt with the Seeger ring.

NOTE
REPEAT THE STEPS TO FIT THE PASSENGER FOOTPEG ON THE OPPOSITE SIDE.

Turning the shock absorbers upside-down and fitting the passenger handgrips

• 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.

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SADDLE

BODYWORK CENTRAL SECTION - SADDLE

pos. Description Type Quantity Torque Notes
1 Saddle release block fixing screw M6x25 2 10 Nm (2.37 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) -

Seat replacement

• Insert the key in the lock and turn it

clockwise.
• Remove the single-seat saddle.

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• Place the two-seat saddle.

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A
Air filter: 43
Air temperature sensor: 67, 78

B
Battery: 61
Brake: 158, 161, 163, 164, 166, 168, 171, 173
Brake calliper: 158, 161
Brake disc: 163, 164
Brake lever:
Brake pads: 166, 168
Brake pump: 171, 173
Bulbs:

C
Clutch: 75
Coil: 72
Connectors: 80

D
Display:

E
ECU: 80, 105
Electrical system: 12, 49, 51, 182
Engine oil: 41
Engine temperature sensor: 65
Exhaust: 153

F
Fork: 112, 114, 118, 119, 123
Front wheel: 110, 165
Fuel: 179
Fuses: 60

H
Handlebar: 111

I
Identification: 10
Instrument panel: 78

M
Maintenance: 8, 39
Maintenance Table:
Mudguard:
O
Oil filter: 43
Oil pressure sensor: 74

R
Rear wheel:
Recommended products: 34
Run/Stop switch: 79

S
Saddle:
Shock absorbers: 128
Side stand: 76
Side stand sensor: 76
Spark plugs:
Speed sensor: 61
Stand: 76
Start-up: 59

T
Tank: 179
Transmission: 12, 40
Tyres: 14

W
Warning lights:
Wiring diagram: 56