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.
Characteristics V7 Classic
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