MOTO GUZZI V7 CLASSIC User manual

SERVICE STATION MANUAL
981078
V7 Classic

SERVICE STATION
MANUAL
V7 Classic
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
setting off, 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 manual 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 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 2008- Moto Guzzi. All rights reserved. Reproduction of this publication in whole or in part is
prohibited. Moto Guzzi - After sales service.
Moto Guzzi trademark is property of Piaggio & C. S.p.A.
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SERVICE STATION MANUAL
V7 Classic
This manual provides the main information to carry out regular maintenance operations on your vehicle.
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 Sectionsmarkedwiththis 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.
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INDEX OF TOPICS
CHARACTERISTICS CHAR
SPECIAL TOOLS S-TOOLS
MAINTENANCE MAIN
ELECTRICAL SYSTEM ELE SYS
ENGINE FROM VEHICLE ENG VE
POWER SUPPLY P SUPP
SUSPENSIONS SUSP
CHASSIS CHAS
BODYWORK BODYW
PRE-DELIVERY PRE DE
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INDEX OF TOPICS
CHARACTERISTICS CHAR
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Rules
Safety rules
Carbon monoxide
If you need to keep the engine running in order to carry out any procedure, please ensure that you do
so in an open or very well ventilated area. Never let the engine run in an enclosed area. If you do work
in an enclosed area, make sure to use a smoke-extraction system.
CAUTION
EXHAUSTEMISSIONSCONTAINCARBONMONOXIDE,APOISONOUSGASWHICHCANCAUSE
LOSS OF CONSCIOUSNESS AND EVEN DEATH.
Fuel
CAUTION
FUEL USED TO POWER INTERNAL COMBUSTION ENGINES IS HIGHLY FLAMMABLE AND CAN
BECOME EXPLOSIVE UNDER SPECIFIC CONDITIONS. IT IS THEREFORE RECOMMENDED TO
CARRY OUT REFUELLING AND MAINTENANCE PROCEDURES IN A VENTILATED AREA WITH
THE ENGINE SHUT OFF. DO NOT SMOKE DURING REFUELLING AND NEAR FUEL VAPOURS,
AVOID ANY CONTACT WITH NAKED FLAMES, SPARKS OR OTHER SOURCES WHICH MAY
CAUSE THEM TO IGNITE OR EXPLODE.
DO NOT DISPOSE OF FUEL INTO THE ENVIRONMENT.
KEEP OUT OF THE REACH OF CHILDREN.
Hot components
The engine and the exhaust system components get very hot and remain in this condition for a certain
time interval after the engine has been shut off. Before handling these components, make sure that you
are wearing insulating gloves or wait until the engine and the exhaust system have cooled down.
Used engine oil and transmission oil
CAUTION
IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN SERVICING THE VEHICLE.
ENGINE OR TRANSMISSION 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 INTO THE ENVIRONMENT
KEEP OUT OF THE REACH OF CHILDREN.
Brake and clutch fluid
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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
BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND AS IT CONTAINS SULPHURIC ACID, IT
CAN CAUSE BURNS WHEN IN CONTACT WITH THE SKIN. WHEN HANDLING BATTERY ELEC-
TROLYTE, WEAR TIGHT-FITTING GLOVES AND PROTECTIVE APPAREL. IF THE ELECTRO-
LYTIC FLUID COMES INTO CONTACT WITH THE SKIN, RINSE WELL WITH ABUNDANT FRESH
WATER. IT IS PARTICULARLY IMPORTANT TO PROTECT YOUR EYES AS EVEN TINY
AMOUNTS OF BATTERY ACID MAY CAUSE BLINDNESS. IF THE FLUID GETS INTO CONTACT
WITH YOUR EYES, WASH WITH ABUNDANT WATER FOR FIFTEEN MINUTES AND CONSULT
AN EYE SPECIALIST IMMEDIATELY. IF THE FLUID IS ACCIDENTALLY SWALLOWED, DRINK
LARGE QUANTITIES OF WATER OR MILK, FOLLOWED BY MILK OF MAGNESIA OR VEGETA-
BLE OIL AND SEEK MEDICAL ADVICE IMMEDIATELY. THE BATTERY RELEASES EXPLOSIVE
GASES; KEEP IT AWAY FROM FLAMES, SPARKS, CIGARETTES OR ANY OTHER HEAT
SOURCE. ENSURE ADEQUATE VENTILATION WHEN SERVICING OR RECHARGING THE BAT-
TERY.
KEEP OUT OF THE REACH OF CHILDREN
BATTERY LIQUID IS CORROSIVE. DO NOT POUR OR SPILL IT, PARTICULARLY ON PLASTIC
COMPONENTS. ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BAT-
TERY TO BE ACTIVATED.
Maintenance rules
GENERAL PRECAUTIONS AND INFORMATION
When repairing, disassembling and reassembling the vehicle, strictly follow the recommendations re-
ported below.
BEFORE DISASSEMBLING COMPONENTS
•Before disassembling components, remove dirt, mud, dust and foreign bodies from the ve-
hicle. Use the special tools designed for this vehicle, as required.
COMPONENTS REMOVAL
•Do not loosen and/or tighten screws and nuts using pliers or other tools other than the
especially designed 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 in order to be identified during assembly.
•Clean and wash the dismantled components carefully using a low-flammability detergent.
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•Keep coupled parts together since they have "adjusted" to each other due to normal wear
and tear.
•Some components must be used together or replaced altogether.
•Keep away from heat sources.
REASSEMBLING COMPONENTS
CAUTION
BEARINGS MUST BE ABLE TO ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTH-
ERWISE THEY NEED REPLACING.
•Only use ORIGINAL Moto Guzzi SPARE PARTS.
•Comply with lubricant and consumables usage 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, split pins and
screws with new ones if their tread is damaged.
•When fitting bearings, make sure to lubricate them well.
•Check that each component is fitted 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 junction surfaces, oil guard rims and washers before refitting them. Smear a light
layer of lithium-based grease on the oil guard rims. Reassemble the oil guard and the bear-
ings with the brand or lot number facing outward (visible side).
ELECTRIC CONNECTORS
Electric connectors must be disconnected as described below as non-compliance with the procedure
so described causes irreparable damage to both the connector and the cable harness:
Press the relevant safety hooks, if any.
•Grip and disconnect the two connectors by pulling them in opposite directions.
•Ifthereare signs of dirt, rust, humidity, etc.,cleantheconnector internal parts carefully using
a pressurised air jet.
•Make sure that the cables are correctly linked to the connector internal terminal ends.
•Then insert the two connectors making sure that they couple correctly (if the relevant hooks
are provided, you will hear them "click" into place).
CAUTION
TO DISCONNECT THE TWO CONNECTORS, DO NOT PULL THE CABLES.
NOTE
THE TWO CONNECTORS CONNECT ONLY FROM ONE SIDE: CONNECT THEM THE RIGHT WAY
ROUND.
TIGHTENING TORQUE
CAUTION
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DO NOT FORGET THAT THE TIGHTENING TORQUE OF ALL FASTENING ELEMENTS ON
WHEELS, BRAKES, WHEEL SPINDLES AND OTHER SUSPENSION COMPONENTS PLAY A KEY
ROLE IN ENSURING THE VEHICLE'S SAFETY AND MUST COMPLY WITH SPECIFIED VALUES.
CHECK THE TIGHTENING TORQUE OF FASTENING PARTS ON A REGULAR BASIS AND AL-
WAYS USE A TORQUE WRENCH TO REASSEMBLE THESE COMPONENTS. FAILURE TO COM-
PLY WITH THESE RECOMMENDATIONS MAY CAUSE ONE OF THESE COMPONENTS TO GET
LOOSE AND EVEN DETACHED, THUS BLOCKING A WHEEL, OR OTHERWISE COMPROMISE
VEHICLE HANDLING. THIS CAN LEAD TO FALLS, WITH THE RISK OF SERIOUS INJURY OR
DEATH.
Running-in
Engine run-in is essential to ensure engine long life and correct operation. Twisty roads and gradients
are ideal to run in engine, brakes and suspensions effectively. Vary your driving speed during run-in.
In this way, you allow for the work of components to be "loaded" and then "unloaded", thus cooling
engine parts.
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.
ITISIMPORTANTTOSTRAIN ENGINE COMPONENTS DURINGRUN-IN,HOWEVER,MAKESURE
NOT TO OVERDO THIS.
CAUTION
ONLY AFTER THE SERVICE AT THE END OF THE RUN-IN PERIOD CAN THE BEST PERFORM-
ANCE OF YOUR VEHICLE BE OBTAINED.
Follow the guidelines detailed below:
•Do not twist the throttle grip abruptly and completely when the engine is working at a low
revs, either during or after run-in.
•During the first 100 km (62 miles) operate the brakes with caution, avoid rough and long
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" TABLE IN THE SCHEDULED MAINTE-
NANCE SECTION TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHI-
CLE.
Vehicle identification
SERIAL NUMBER POSITION
These numbers are necessary for vehicle registration.
NOTE
ALTERING IDENTIFICATION NUMBERS CAN BE SERIOUSLY PUNISHED BY LAW, PARTICU-
LARLY MODIFYING THE CHASSIS NUMBER WILL IMMEDIATELY INVALIDATE THE WARRAN-
TY.
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This number consists of numbers and letters, as in
the example shown below.
ZGULW00008MXXXXXX
KEY:
ZGU: WMI (World manufacturer identifier) code;
LW: model;
000: version variation;
0: digit free
8: variable year of manufacture (8 - for 2008)
M: production plant (M= Mandello del Lario);
XXXXXX: progressive number (6 digits);
CHASSIS NUMBER
The chassis number is stamped on the right 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 800 mm (31.5 in)
Max. height 1115 mm (43.9 in)
Saddle height 805 mm (31.69 in)
Wheelbase 1435 mm (56.5 in)
Minimum ground clearance 182 mm (7.16 in)
Kerb weight 198 kg (436 lb)
Engine
ENGINE
Specification Desc./Quantity
Type 90° transversal V-twin, four stroke
Number of cylinders 2
Cubic capacity 744 cm³ (45.40 cu.in)
Bore / stroke 80x74 mm (3.14x2.91 in)
Compression ratio 9.6 : 1
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Specification Desc./Quantity
Starter Electronic
Engine revs at idle speed 1100 +/- 100 rpm
Intake valve clearance 0.10 mm (0.0039 in)
Outlet valve clearance 0.15 mm (0.0059 in)
Clutch dry single-disc clutch with anti-vibration buffers
Lubrication system Pressure system regulated by valves and a trochoidal pump
Air filter dry cartridge air filter
Cooling air
Transmission
TRANSMISSION
Specification Desc./Quantity
Gearbox / Type mechanical, 5 speeds with foot lever on the left-hand side of
the engine.
Main transmission with gears, ratio: 16 / 21 = 1 : 1.3125
1st gear ratios 11 / 26 = 1 : 2.3636
2nd gear ratios 14 / 23 = 1 : 1.6429
3rd gear ratios 18 / 23 = 1 : 1.2778
4th gear ratios 18 / 19 = 1 : 1.0556
5th gear ratios 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 UKgal; 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 2
Vehicle maximum load 203 kg (447 lb) (rider + passenger + luggage)
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
BULBS
Specification Desc./Quantity
Low-/ high-beam light (halogen) 12 V - 55 W / 60 W H4
Front daylight running light 12V - 5W
Turn indicator light 12 V - 10 W (orange RY 10 W bulb)
License plate light 12V - 5 W
Characteristics V7 Classic
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Specification Desc./Quantity
Rear tail light /stop lights 12 V - 5 / 21 W
Instrument panel 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 inclination angle 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 swinging arm in die-cast light alloy, 2 shock absorbers with ad-
justable spring preloading
Wheel travel 100 mm (3.93 in)
SIZES A AND B
Specification Desc./Quantity
Size A 692 mm (27.24 in)
Size B 186 mm (7.32 in)
Brakes
BRAKES
Specification Desc./Quantity
Front stainless steel floating disc, Ø 320 mm (12.59 in), callipers with
4 different and counteracting plungers
Rear stainless steel disc; Ø 260 mm (10.24 in)
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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 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 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 SUPPLY
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
Name Torque in Nm
Tank to chassis support rubber rings retainer - M8x14 (2) 25 Nm (18.44 lbf ft)
Cradle front retainer - M10x30 (2+2) 50 Nm (36.88 lbf ft)
Engine / gearbox to chassis retainer - M10 (1+1) 50 Nm (36.88 lbf ft)
Gearbox to chassis retainer - M12x55 (2) 50 Nm (36.88 lbf ft)
Stand to cradles transverse retainer - M10x260 (1) 50 Nm (36.88 lbf ft)
Stand to cradles transverse retainer - M8 (1+1) 25 Nm (18.44 lbf ft)
Battery housing plate retainer - M8x16 (4) 25 Nm (18.44 lbf ft)
Left and right rider footrest support to chassis retainer - M8x20
(2+2) 25 Nm (18.44 lbf ft) - Loctite 243
Left and right passenger footrest support to chassis retainer -
M8x16 (2+2) 25 Nm (18.44 lbf ft) - Loctite 243
FOOTRESTS AND LEVERS
Name Torque in Nm
Footrest rubber retainer - M6x12 (8) 10 Nm (7.38 lbf ft)
Gear shift lever cable retainer (nut) - M6x1 (2) 10 Nm (7.38 lbf ft)
Gear transmission lever retainer - M6x20 (1) 10 Nm (7.37 lbf ft)
Preselector lever retainer - M6x20 (1) 10 Nm (7.38 lbf ft)
SIDE STAND
Name Torque in Nm
Side stand retainer bolt - M10x1.25 (1) 10 Nm (7.38 lbf ft)
Switch retainer - M5x16 (2) 6 Nm (4.42 lbf ft)
Pin lock nut - M10x1.25 (1) 30 Nm (22.13 lbf ft)
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SWINGARM
Name Torque in Nm
Swingarm on gearbox retainer - M20x1 (2) 0 Nm (0 lbf ft) - in support without preloading
Lock nut on pin retainer - M20x1 (2) 50 Nm (36.88 lbf ft) - keep the pin firmly in place
Swingarm to gearcase retainer - M8 (4) 25 Nm (18.44 lbf ft) - keep the pin firmly in place
FRONT SUSPENSION
Name Torque in Nm
Fork stem on lower/upper plate retainer - M10x40 (2+2) 50 Nm (36.88 lbf ft)
Headstock nut - M23x1 (1) 50 Nm (36.88 lbf ft)
Headstock ring nut - M25x1 (1) 7 Nm (5.16 lbf ft) - the headstock should turn freely
Fork stem cap (1+1) 50 Nm (36.88 lbf ft)
Fork hub cap - M6x30 (2) 10 Nm (7.37 lbf ft)
REAR SUSPENSION
Name Torque in Nm
Shock absorber to chassis upper retainer - M6x35 (1+1) 10 Nm (7.37 lbf ft) - Loctite 243
Left shock absorber to swingarm retainer - M10x1.5 (1) 35 Nm (25.81 lbf ft)
Right shock absorber stud bolt to housing retainer - M12x1.5
(1) 35 Nm (25.81 lbf ft)
Right shock absorber to stud bolt retainer - M6x16 (1) 10 Nm (7.37 lbf ft) - Loctite 243
AIR FILTER CASING
Name Torque in Nm
Filter casing cover retainer (4) 3 Nm (2.21 lbf ft)
Filter casing to chassis retainer (3) 3 Nm (2.21 lbf ft)
Air temperature sensor retainer (2) 2 Nm (1.47 lbf ft)
EXHAUST
Name Torque in Nm
Exhaust pipe to engine retainer - M6 (2+2) 10 Nm (7.37 lbf ft)
Exhaust pipe to compensator retainer (clamp) - M6 (2) 10 Nm (7.38 lbf ft)
Exhaust pipe to silencer retainer (clamp) - M6 (1+1) 10 Nm (7.37 lbf ft)
Lambda probe retainer - M18x1.5 (1) 38 Nm (28.03 lbf ft)
Mufflers to support retainer - M8x25 (4) 25 Nm (18.44 lbf ft) - Loctite 601
Right and left heat guard bulkhead retainer - M6x12 (2+2) 10 Nm (7.37 lbf ft) - Loctite 270
Muffler support to chassis retainer - M8 (1) 25 Nm (18.44 lbf ft)
FRONT WHEEL
Name Torque in Nm
Brake disc retainer - M8x20 (6) 25 Nm (18.44 lbf ft) - Loctite 243
Wheel pin - M18x1.5 (1) 80 Nm (59 lbf ft)
REAR WHEEL
Name Torque in Nm
Brake disc retainer - M8x25 (6) 25 Nm (18.44 lbf ft) - Loctite 243
Wheel bolt + nut - M16 (1) 120 Nm (88.51 lbf ft)
Screw + lock clamp nut - M10 (1) 30 Nm (22.13 lbf ft)
FRONT BRAKING SYSTEM
Name Torque in Nm
Front calliper retainer - M10x30 (2) 50 Nm (36.88 lbf ft)
REAR BRAKING SYSTEM
Name Torque in Nm
Rear calliper retainer - M8x35 (2) 25 Nm (18.44 lbf ft)
Calliper holding plate to swingarm retainer - M16x1 (1) 25 Nm (18.44 lbf ft)
Rear brake lever nut - M8 (1) 25 Nm (18.44 lbf ft)
Rear brake fluid reservoir retainer - M5x15 (1) 6 Nm (4.42 lbf ft)
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Name Torque in Nm
Lever lock spacer retainer - M6x16 (1) 10 Nm (7.37 lbf ft)
Rear brake rod lock nut - M6 (1) manual
Brake pump retainer - M6x25 (2) 10 Nm (7.37 lbf ft)
HANDLEBAR AND CONTROLS
Name Torque in Nm
Retainer for handlebar support U-bolts on steering plate -
M10x60 (2) 50 Nm (36.88 lbf ft)
Handlebar lock U-bolts retainer - M8x30 (2+2) 25 Nm (18.44 lbf ft)
Right and left light switch retainer - M5 (2) 1.5 Nm (1.11 lbf ft)
Retainer for clutch and brake pump U-bolts - M6 (2+2) 10 Nm (7.37 lbf ft)
Mirror - M10 (1+1) Manual
ELECTRICAL SYSTEM
Name Torque in Nm
Voltage regulator retainer - M6x30 (2) 10 Nm (7.37 lbf ft)
Horn retainer (screw+nut) - M6x16 (1) 10 Nm (7.37 lbf ft)
Coil retainer - AT M4x25 (4) 3 Nm (2.21 lbf ft)
Fuse box bracket retainer - M5x12 (2) 4 Nm (2.95 lbf ft)
Control unit retainer (4) 3 Nm (2.21 lbf ft)
Battery housing bracket retainer (2) 3 Nm (2.21 lbf ft)
Odometer sensor to calliper holding plate retainer - M6x12 (1) 10 Nm (7.37 lbf ft)
INSTRUMENT PANEL AND LIGHTS
Name Torque in Nm
Instrument panel to light support retainer - M6 (3+3) 10 Nm (7.37 lbf ft)
Headlamp retainer - M8x30 (2) 15 Nm (11.06 lbf ft)
Front and rear turn indicator retainer (screw + nut) - M6 (2+2) 5 Nm (3.69 lbf ft)
Rear light support to mudguard retainer - M5x14 (3) 4 Nm (2.95 lbf ft)
FUEL PUMP FLANGE
Name Torque in Nm
Pump support to tank retainer - M5x16 (6) 6 Nm (4.42 lbf ft)
FUEL TANK
Name Torque in Nm
Cap flange to fuel tank retainer - M5x12 (5) 4 Nm (2.95 lbf ft)
Tank rear retainer - M8x45 (1) 25 Nm (18.44 lbf ft)
CHASSIS / FAIRINGS (FRONT)
Name Torque in Nm
Stabiliser plate to fork retainer - M8x40 (4) 15 Nm (11.06 lbf ft) - Loctite 243
Front mudguard to stabiliser plate retainer - M6x11 (4) 10 Nm (7.37 lbf ft) - Loctite 243
Headstock protection panel retainer - M5x12 (1) 4 Nm (2.95 lbf ft)
CHASSIS / FAIRINGS (CENTRE)
Name Torque in Nm
Right and left throttle body protection retainer - M5x14 (2) 4 Nm (2.95 lbf ft)
Right and left fairing retainer - M5x9 (1+1) 4 Nm (2.95 lbf ft)
CHASSIS/ FAIRINGS (REAR)
Name Torque in Nm
Rear mudguard front and central retainer - M6 (2+1) 10 Nm (7.37 lbf ft)
Rear mudguard rear retainer - M8x30 (2) 25 Nm (18.44 lbf ft)
Retroreflector to support retainer - M5 (1) 4 Nm (2.95 lbf ft)
Retroreflector support to license plate holder retainer - M5x10
(2) 4 Nm (2.95 lbf ft)
License plate holder to mudguard reinforcement retainer (3) 3 Nm (2.21 lbf ft)
Characteristics V7 Classic
CHAR - 16
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FINISHINGS
Name Torque in Nm
Ignition lock retainer - shear head screw - M8x15 (1) at the point of failure
Ignition lock retainer - M8x16 (1) 25 Nm (18.44 lbf ft)
Saddle opening lock retainer - M6x25 (2) 10 Nm (7.37 lbf ft)
HEADS
Name Torque in Nm
Screws fixing the engine head covers 10 Nm (7.37 lbf ft)
Ignition spark plug retainer 25 Nm (18.43 lbf ft)
CRANKCASE
Name Torque in Nm
Heads - cylinders to crankcase fixing nut (M10) 40 - 42 Nm (29.50 - 30.97 lbf ft)
Heads - cylinders to crankcase fixing nut (M8) 28 - 30 Nm (20.65 - 22.12 lbf ft)
Nuts joining crankcase halves (M8) 22 - 25 Nm (16.22 - 18.43 lbf ft)
Nuts joining crankcase halves (M10) 40 - 42 Nm (29.50 - 30.97 lbf ft)
Timing system cover fixing screws 10 Nm (7.37 lbf ft)
Oil sump fixing screws 10 Nm (7.37 bf ft)
Valve cover insert fixing screw 5 Nm (3.68 lbf ft)
CRANKSHAFT - FLYWHEEL
Name Torque in Nm
Connecting rod screws 30 - 32 Nm (22.12 - 23.60 lbf ft)
Flywheel to crankshaft fixing screw 40 Nm (29.50 lbf ft)
Crown gear fixing screw 10 Nm (7.37 lbf ft)
TIMING SYSTEM
Name Torque in Nm
Camshaft to crankcase retaining joint 30 Nm (22.12 lbf ft)
Gear on camshaft fixing screws 25 Nm (18.43 lbf ft)
Tone wheel fixing screw 25 Nm (18.43 lbf ft)
ELECTRIC STARTING SYSTEM
Name Torque in Nm
Starter motor fixing screws 25 Nm (18.43 lbf ft)
FUEL SUPPLY CONTROL UNIT
Name Torque in Nm
Injection cap fixing screws M5 4 Nm (2.95 lbf ft)
Screws fixing intake pipe to the heads 10 Nm (7.37 lbf ft)
OIL PUMP
Name Torque in Nm
Oil pressure sensor 8 - 10 Nm (5.90 - 7.37 lbf ft)
Oil pump to crankcase fixing screws 10 Nm (7.37 lbf ft)
Filtering cartridge sealing cover fixing screw 25 Nm (18.43 lbf ft)
GENERATOR
Name Torque in Nm
Generator stator fixing screws 5 Nm (3.68 lbf ft)
Generator rotor nut 80 Nm (59.00 lbf ft)
GEAR
Name Torque in Nm
Clutch shaft fixing nut 100 Nm (73.75 lbf ft)
Main shaft lock nuts 65 Nm (47.94 lbf ft)
V7 Classic Characteristics
CHAR - 17
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Name Torque in Nm
Cover to gearbox fixing screws 10 Nm (7.37 lbf ft)
Gearbox to clutch bell cover fixing screws 10 Nm (7.37 lbf ft)
Index lever fixing nut 6 Nm (4.42 lbf ft)
Recommended products chart
RECOMMENDED PRODUCTS
Product Description Specifications
AGIP RACING 4T 10W-60 Engine oil SAE 10W - 60. As an alternative for rec-
ommended oils use top-branded oils that
meet or exceed the requirements of
CCMC G-4 API SG specifications.
AGIP GEAR MG SAE 85W-140 Transmission oil -
AGIP GEAR MG/S SAE 85W-90 Gearbox oil -
AGIP FORK 7.5W Fork oil SAE 5W / SAE 20W
AGIP GREASE SM2 Lithium grease with molybdenum for
bearings and other points needing lubri-
cation
NLGI 2
Neutral grease or petroleum jelly. Battery poles
AGIP BRAKE 4 / BRAKE 5.1 Brake fluid As an alternative for recommended fluids
use top-branded fluids that meet or ex-
ceed the requirements of SAE J1703,
NHTSA 116 DOT 4, ISO 4925 Synthetic
fluid specifications.
NOTE
USE ONLY NEW BRAKE FLUID. DO NOT MIX DIFFERENT BRANDS OR TYPES OF OIL WITHOUT
CHECKING THEIR BASE COMPATIBILITY.
Characteristics V7 Classic
CHAR - 18
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INDEX OF TOPICS
SPECIAL TOOLS S-TOOLS
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SPECIAL TOOLS
Stores code Description
19.92.61.00 Punch for sealing ring of bevel gear pair
pinion
19.92.88.00 Bevel gear pair 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 pair pin-
ion
Special tools V7 Classic
S-TOOLS - 20
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