2012-2013 Moto Guzzi V7 Stone V7 Special V7 Racer Service & Repair Manual

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

MANUALE STAZIONE DI SERVIZIO V7 Stone - V7 Special - V7 Racer THE VALUE OF SERVICE As a result of continuous updates and specific technical training programmes for Moto Guzzi products, only Moto Guzzi Official Network mechanics know this vehicle fully and have the specific tools necessary 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, its regular maintenance and the use of original Moto Guzzi spare parts only are essential factors! For information on the nearest Official Dealer and/or Service Centre consult our website: www.motoguzzi.com Only by requesting Moto Guzzi original spare parts can you be sure of purchasing products that were developed and tested during the actual vehicle design stage. All Moto Guzzi original spare parts undergo quality control procedures to guarantee reliability and durability. The descriptions and images in this publication are given for illustrative purposes only and are not binding. While the basic characteristics as described and illustrated in this booklet remain unchanged, Piaggio & C. S.p.A. reserves the right, at any time and without being required to update this publication beforehand, to make any changes to components, parts or accessories, which it considers necessary to improve the product or which are required for manufacturing or construction reasons. Not all versions/models shown in this publication are available in all countries. The availability of individual versions/models should be confirmed with the official Moto Guzzi sales network. The Moto Guzzi trademark is the property of Piaggio & C. S.p.A. © Copyright 2012 - Piaggio & C. S.p.A. All rights reserved. Reproduction of this publication in whole or in part is prohibited. Piaggio & C. S.p.A. Viale Rinaldo Piaggio, 25 - 56025 PONTEDERA (PI), Italy www.piaggio.com

MANUALE STAZIONE DI SERVIZIO V7 Stone - V7 Special - V7 Racer Questo manuale fornisce le informazioni principali per le procedure di normale intervento sul veicolo. Questa pubblicazione è indirizzata ai Concessionari Moto Guzzi e ai loro meccanici qualificati; molte nozioni sono state volutamente omesse, perché giudicate superflue. Non essendo possibile includere nozioni meccaniche complete in questa pubblicazione, le persone che utilizzano questo manuale devono essere in possesso sia di una preparazione meccanica di base, che di una conoscenza minima sulle procedure inerenti ai sistemi di riparazione dei motoveicoli. Senza queste conoscenze, la riparazione o il controllo del veicolo potrebbe essere inefficiente o pericolosa. Non essendo descritte dettagliatamente tutte le procedure per la riparazione, e il controllo del veicolo, bisogna adottare particolare attenzione al fine di evitare danni ai componenti e alle persone. Per offrire al cliente maggiore soddisfazione dall. uso del veicolo, Moto Guzzi s.p.a. si impegna a migliorare continuamente i propri prodotti e la relativa documentazione. Le principali modifiche tecniche e modifiche alle procedure per le riparazioni del veicolo vengono comunicate a tutti i Punti Vendita Moto Guzzi e alle Filiali nel Mondo. Tali modifiche verranno apportate, nelle edizioni successive di questo manuale. Nel caso di necessità o dubbi sulle procedure di riparazione e di controllo, interpellare il REPARTO ASSISTENZA Moto Guzzi, il quale sarà in grado di fornirvi qualsiasi informazione al riguardo, oltre a fornire eventuali comunicazioni su aggiornamenti e modifiche tecniche applicate al veicolo. 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 POWER SUPPLY P SUPP SUSPENSIONS SUSP CHASSIS CHAS BODYWORK BODYW PRE-DELIVERY PRE DE

INDEX OF TOPICS CHARACTERISTICS CHAR

Rules Safety rules Carbon monoxide If you need to keep the engine running while working on the vehicle, please ensure that you do so in an open or very well ventilated area. Never let the engine run in an enclosed area. If you do work in an enclosed area, make sure to use a fume extraction system. 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 OR NEAR FUEL VAPOUR. AVOID ANY CONTACT WITH NAKED FLAME, SPARKS OR OTHER HEAT SOURCES WHICH MAY CAUSE IGNITION OR EXPLOSION. DO NOT ALLOW FUEL TO DISPERSE INTO 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. 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. 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. Brake and clutch fluid V7 Stone - V7 Special - V7 Racer Characteristics CHAR - 7

BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAINTED SURFACES. WHEN SERVICING THE BRAKING OR THE CLUTCH SYSTEM PROTECT THESE COMPONENTS WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THESE SYSTEMS. BRAKE AND CLUTCH FLUIDS ARE EXTREMELY HARMFUL FOR YOUR EYES. IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THEM IMMEDIATELY WITH PLENTY OF 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, MAY CAUSE BURNING IF IT COMES INTO 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. IN THE EVENT OF CON- TACT WITH THE EYES, RINSE WITH PLENTY OF WATER FOR FIFTEEN MINUTES AND CON- SULT AN EYE SPECIALIST IMMEDIATELY. IF THE FLUID IS ACCIDENTALLY SWALLOWED, DRINK LARGE QUANTITIES OF WATER OR MILK, FOLLOWED BY MILK OF MAGNESIA OR VEGETABLE OIL AND SEEK MEDICAL ADVICE IMMEDIATELY. THE BATTERY RELEASES EX- PLOSIVE GASES; KEEP IT AWAY FROM FLAMES, SPARKS, CIGARETTES OR ANY OTHER HEAT SOURCES. ENSURE ADEQUATE 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 BEING ACTIVATED. Maintenance rules GENERAL PRECAUTIONS AND INFORMATION When repairing, dismantling and reassembling the vehicle follow the recommendations reported below carefully. BEFORE REMOVING 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 the positions on all connection joints (pipes, cables, etc.) before separating them, and identify them with different 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. Characteristics V7 Stone - V7 Special - V7 Racer CHAR - 8

• Keep mated parts together since they have "adjusted" to each other due to normal wear. • Some components must be used together or replaced altogether. • Keep away from heat sources. REASSEMBLY OF COMPONENTS CAUTION BEARINGS MUST BE ABLE TO ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE: OTH- ERWISE, 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 vehicle 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). ELECTRIC CONNECTORS Electric connectors must be disconnected as described below; failure to comply with this procedure causes irreparable damage to both the connector and the cable harness: Press the relevant safety hooks, if any. • 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 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 TORQUES CAUTION V7 Stone - V7 Special - V7 Racer Characteristics CHAR - 9

IN THE EVENT THAT A SELFBRAKING NUT IS UNSCREWED, IT IS NECESSARY TO REPLACE IT WITH A NEW ONE. CAUTION DO NOT FORGET THAT THE TIGHTENING TORQUES OF ALL FASTENING ELEMENTS ON WHEELS, BRAKES, WHEEL BOLTS 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 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 riding speed during the run- in. This ensures that components operate under both "loaded" and "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 DISCS 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 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) 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 CHASSIS NUMBER IMMEDIATELY VOIDS THE WARRANTY. Characteristics V7 Stone - V7 Special - V7 Racer CHAR - 10

2012-2013 Moto Guzzi V7 Stone V7 Special V7 Racer Service & Repair Manual

You're Reading a Preview

Recently Viewed