SERVICE STATION MANUAL

2Q000466

V7 E5 Special-Stone
 SERVICE STATION
MANUAL

V7 E5 Special-Stone

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:
[Link]
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 should be checked with the Official Moto Guzzi sales network.
The Moto Guzzi brand is owned by Piaggio & C. S.p.A.
© Copyright 2021 - 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
[Link]
 SERVICE STATION MANUAL
V7 E5 Special-Stone
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 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

PRE-DELIVERY PRE DE

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
INDEX OF TOPICS

PRE-DELIVERY PRE DE
V7 E5 Special-Stone Pre-delivery

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
- 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.

PRE DE - 7
Pre-delivery V7 E5 Special-Stone

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 THE LIFE OF THE BATTERY.
CAUTION

WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG-
ATIVE ONE, AND PERFORM THE REVERSE OPERATION DURING REMOVAL.
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. THE BATTERY RELEASES EXPLOSIVE GASES;
KEEP IT AWAY FROM FLAMES, SPARKS, CIGARETTES OR ANY OTHER HEAT SOURCES. EN-
SURE ADEQUATE VENTILATION WHEN SERVICING OR RECHARGING THE BATTERY.
KEEP OUT OF THE REACH OF CHILDREN.
BATTERY LIQUID IS CORROSIVE. DO NOT POUR OR SPILL ON PLASTIC COMPONENTS IN
PARTICULAR. ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BATTERY
BEING ACTIVATED.
CAUTION

NEVER USE FUSES WITH A CAPACITY HIGHER THAN THAT RECOMMENDED. THE USE OF A
FUSE OF UNSUITABLE CAPACITY MAY RESULT IN SERIOUS DAMAGES TO THE WHOLE VE-
HICLE OR EVEN CAUSE A FIRE.
TRADITIONAL BATTERY ACTIVATION PRO-
CEDURE

• Place the battery on a flat surface.

• Remove the cell's protective sticker.
• Take the acid container.
• Remove the cap 1 of the container 2.
• Place the container upside down, per-
pendicularly above the battery, align-
ing the outlets with the battery cells.
• Apply pressure to the container to
break the seals. The liquid will begin to
flow into the cells.

PRE DE - 8
V7 E5 Special-Stone Pre-delivery

• Check that air bubbles come out of the

cells; let the liquid flow into the cells for
at least 20 minutes.
• If no air bubbles escape and the liquid
does not flow, tap lightly on the bottom
of the container until the liquid begins
to flow into the cells. Never remove the
container from the battery, pierce it or
cut it to facilitate the exit of the liquid.
• Make sure the liquid container is com-
pletely empty before removing it.
• Allow the battery to stand for at least 1
hour, before starting the charging proc-
ess, without closing the six cells. This
operation is extremely important in or-
der to have the best battery perform-
ance over time.
• Recharge the battery following the
specifications indicated on the battery
(see photo ) and using a suitable bat-
tery charger.
NOTE
IN THE SHOWN EXAMPLE IT IS IMPORTANT TO USE A
BATTERY CHARGER WITH 1.2 AMPERE (CHARGING TIME
5-10 HOURS) OR 5 AMPERE (CHARGING TIME 1 HOUR).

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

Road test
- Cold start
- Instrument panel operation
- Response to throttle control
- Stability when accelerating and braking
- Front and rear brake efficiency

PRE DE - 9
Pre-delivery V7 E5 Special-Stone

- 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 SINCE THE TYRES MAY
BURST.
CAUTION

CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.

Specific operations for the vehicle

INSTALLAZIONE SPECCHI RETROVISORI LATERALI

(IF AVAILABLE)

PRE DE - 10
V7 E5 Special-Stone Pre-delivery

• Svitare il dado che blocca i componenti

dello specchio e rimuoverlo prestando
particolare attenzione al verso di mon-
taggio delle molle a tazza (1) che dev-
ono avere la parte concava verso
l'esterno.

• In caso di mancanza del grasso, appli-

care un velo su ambo i lati delle molle
a tazza (1).

• Applicare la loctite 243 sul tratto filetat-

to della vite M6.

PRE DE - 11
Pre-delivery V7 E5 Special-Stone

• Serrare alla coppia di 10 Nm (7.38 lbf

ft) la vite per il fissaggio dello specchio
retrovisore a manubrio.

• Mantenendo ferma la vite, ruotare da

ambo i lati lo specchio per un paio di
volte.

PRE DE - 12
INDEX OF TOPICS

CHARACTERISTICS CHAR
Characteristics V7 E5 Special-Stone

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

FUEL USED TO DRIVE EXPLOSION ENGINES IS HIGHLY INFLAMMABLE AND CAN BECOME
EXPLOSIVE UNDER SPECIFIC CONDITIONS. IT IS THEREFORE RECOMMENDED TO CARRY
OUT REFUELLING AND MAINTENANCE PROCEDURES IN A VENTILATED AREA WITH THE EN-
GINE 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 parts
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.

Used engine oil and transmission oil

CAUTION

WHEN CARRYING OUT MAINTENANCE OPERATIONS, IT IS ADVISABLE TO WEAR PROTEC-

TIVE IMPERMEABLE GLOVES.
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.

CHAR - 14
V7 E5 Special-Stone Characteristics

Brake and clutch fluid

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. THE BATTERY RELEASES EXPLOSIVE GASES;
KEEP IT AWAY FROM FLAMES, SPARKS, CIGARETTES OR ANY OTHER HEAT SOURCES. EN-
SURE ADEQUATE VENTILATION WHEN SERVICING OR RECHARGING THE BATTERY.
KEEP OUT OF THE REACH OF CHILDREN.
BATTERY LIQUID IS CORROSIVE. DO NOT POUR OR SPILL ON PLASTIC COMPONENTS IN
PARTICULAR. ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BATTERY
BEING ACTIVATED.

Maintenance rules

GENERAL PRECAUTIONS AND INFORMATION

When repairs, disassembly and reassembly of the vehicle is carried out, follow the following recom-
mendations strictly.

BEFORE DISASSEMBLING COMPONENTS

• Remove the dirt, mud, dust and foreign objects from the vehicle before disassembling com-
ponents. Wherever required, use the special tools designed for this vehicle.

DISASSEMBLING COMPONENTS

• Do not loosen and/or tighten the screws and nuts using pliers or other tools, but always use
the specific wrench.
• Mark the positions on all the connection joints (hoses, cables, etc.) before separating them
and identify them with different distinctive marks.
• Each piece should be clearly marked in order to be identified during the installation phase.
• Carefully clean and wash the disassembled components with detergents with a low flam-
mability grade.

CHAR - 15
Characteristics V7 E5 Special-Stone

• Keep the coupled parts together because they have "adapted" to one another following
normal wear.
• Some components must be used together or replaced entirely.
• Keep away from heat sources.

REASSEMBLING THE COMPONENTS

CAUTION
THE BEARING MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE
THEY MUST 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), cotter 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
The electrical connectors should be disconnected as follows. Failure to observe these procedures will
cause irreparable damage to the connector and the wiring:
If present, press on the specific safety catches.
• Grip the two connectors and unplug them, pulling them apart in opposite directions.
• If there is dirt, rust, moisture, etc., carefully clean the inside of the connector using pressur-
ised air.
• Ensure that the cables make correct contact with the terminals inside the connectors.
• Then plug in the two connectors, ensuring correct coupling (if the specific catches are
present, you will hear a typical "click").
CAUTION
TO UNPLUG THE TWO CONNECTORS, DO NOT PULL ON THE CABLES.
NOTE
THE TWO CONNECTORS CAN BE PLUGGED IN ONLY IN ONE DIRECTION, THEREFORE JOIN
THEM TOGETHER IN THE RIGHT DIRECTION.
TIGHTENING TORQUE
CAUTION

CHAR - 16
V7 E5 Special-Stone Characteristics

IN THE EVENT THAT A SELFBRAKING NUT IS UNSCREWED, IT IS NECESSARY TO REPLACE

IT WITH A NEW ONE.
CAUTION
REMEMBER THAT THE TIGHTENING TORQUE FOR ALL THE FIXING ELEMENTS LOCATED ON
WHEELS, BRAKES, WHEEL AXLES AND OTHER SUSPENSION COMPONENTS PLAY A FUN-
DAMENTAL ROLE IN GUARANTEEING THE SAFETY OF THE VEHICLE AND MUST BE KEPT AT
THE PRESCRIBED VALUES. REGULARLY CHECK THE TIGHTENING TORQUE OF THE FIXING
ELEMENTS AND ALWAYS USE A TORQUE WRENCH WHEN REFITTING. IF THESE WARNINGS
ARE NOT OBSERVED, ONE OF THESE COMPONENTS COULD LOOSEN AND COME OFF,
BLOCKING A WHEEL OR CAUSING OTHER PROBLEMS THAT WOULD COMPROMISE MA-
NOEUVRABILITY, LEADING TO A CRASH WITH THE RISK OF SERIOUS INJURY OR EVEN
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
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 these guidelines:

• 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.

CHAR - 17
Characteristics V7 E5 Special-Stone

CHASSIS NUMBER
The chassis number is stamped on the RH side of
the headstock.
This number consists of numbers and letters, as in
the example shown below.
ZGULD00017MXXXXXX
KEY:
ZGU: WMI (World Manufacturer Identifier) code;
LD: model;
000: version;
0: free digit
19: variable year of manufacture (19 - for 2019)
M: production plant (M= Mandello del Lario);
XXXXXX: serial number (6 digits);

ENGINE NUMBER
The engine number is stamped on the left side,
close to the engine oil level check cap.

Dimensions and mass

DIMENSIONS AND MASS

Specification Desc./Quantity
Max. length. 2165 mm (85.24 in)
Max. width 800 mm (31.50 in)
Max. height 1,100 mm (43.31 in)
Wheelbase 1,450 mm (57.09 in)
Kerb weight (Stone) 218 kg (481 lb)
Kerb weight (Special) 223 kg (492 lb)

Engine

ENGINE
Specification Desc./Quantity
Type traverse-mounted twin-cylinder four-stroke V 90°
Number of cylinders 2
Engine capacity 853 cc (52.05 cu in)
Bore / stroke 84x77 mm (3.30x3.03 in)
Compression ratio 10.5 +/- 0.5: 1
Starting Electric

CHAR - 18
V7 E5 Special-Stone Characteristics

Specification Desc./Quantity
Idle engine speed 1,250 +/- 100 (rpm)
Clutch single disc dry clutch with flexible coupling
Lubrication system pressure-fed, controlled by valves and trochoidal pump
Air filter cartridge-type dry filter
Cooling air

Transmission

GEARBOX
Specification Desc./Quantity
Type mechanical, 6 speeds with foot lever on the left hand side of
the engine

TRANSMISSION
Specification Desc./Quantity
Primary drive with gears, ratio: 18 / 23 = 1 : 1.277
Gear ratios, 1st gear 16 / 39 = 1: 2.437
Gear ratios, 2nd gear 18 / 32 = 1: 1,777
Gear ratios, 3rd gear 21 / 28 = 1: 1,333
Gear ratios, 4th gear 24 / 26 = 1: 1.083
Gear ratios, 5th gear 25 / 24 = 1: 0.96
Gear ratios, 6th gear 28 / 24 = 1: 0.857
Final drive with shaft, ratio 8 / 33 = 1 : 4,125

Capacities

CAPACITY
Specification Desc./Quantity
Fuel tank capacity (including reserve) 21 l (4.62 UK gal; 5.55 US gal)
Fuel tank reserve capacity 4 l (0.88 UK gal; 1.06 US gal)
Engine oil Oil change and oil filter replacement: 1750 cm³ (106.79 [Link])
Gearbox oil 500 cm³ (30.51 [Link])
Transmission oil 180 cc (10.37 cu in)
Seats 2
Maximum weight limit (Stone) 428 kg (944 lb) (rider + passenger + luggage)
Maximum weight limit (Special) 433 kg (954 lb) (rider + passenger + luggage)

Electrical system

ELECTRICAL SYSTEM
Specification Desc./Quantity
Battery 12 V - 12 Ah
Permanent magnet alternator 12V - 430W
Fuses (halogen headlamps) 10 - 7.5 - 15 - 5 (2) - 30 - 20 A
(led headlamps) 10 - 7.5 - 15 - 5 (2) - 30 - 20 A
High beam/low beam light (halogen 12 V - 55 W / 60 W H4) or (led)
Front DRL (halogen 12 V - 5 W) or (led)
taillight /stop lights (halogen 12 V - 5 / 21 W) or (led)
Turn indicators (halogen 12 V - 10 W (RY 10 W orange bulb)) or (led)

SPARK PLUGS
Specification Desc./Quantity
Standard NGK IR MR8BI-8
Spark plug electrode gap 0.8 mm (0.031 in)
Resistance 5 kOhm

CHAR - 19
Characteristics V7 E5 Special-Stone

INDICATOR LAMPS
Specification Desc./Quantity
Gearbox in neutral LED
Turn indicators LED
Fuel reserve LED
High beam light LED
General alarm LED
MI warning light LED
ABS warning light LED
MGCT warning light LED

Frame and suspensions

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

CHASSIS
Specification Desc./Quantity
Type Modular double cradle, high-strength steel tubular chassis
Steering rake angle 26,4°
Trail (no rider or passenger - wheels on the ground - without 104.2 mm (4.10 in)
use of side stand)

SUSPENSIONS
Specification Desc./Quantity
Front hydraulic telescopic fork, Ø 40 mm (1.57 in)
Travel 137 mm (5.39 in)
Rear (standard) Swingarm in die-cast light alloy, 2 shock absorbers with ad-
justable spring pre-loading
Rear (race) Swingarm in die-cast light alloy, 2 shock absorbers with ad-
justable extension, compression and spring pre-loading
Stroke (standard) 98 mm (3.86 in)
Stroke (race) 75 mm (2.95 in)

Brakes

BRAKES
Specification Desc./Quantity
Front Ø 320-mm (12.59 in) stainless steel floating disc, calliper with
4 different and counteracting plungers
Rear 260 mm (10.24 in) stainless steel disc, floating calliper with two
22 mm (0.87 in) diameter pistons

CHAR - 20
V7 E5 Special-Stone Characteristics

Wheels and tyres

WHEEL RIMS
Specification Desc./Quantity
Type spoked wheels with alloy rims, for tyres with inner tubes, or
alloy tubes wheels for tubeless tyres.
Front 2.5''x18''
Rear 4.25" x 17''

TYRES
Specification Desc./Quantity
Front (size) 100 / 90 - 18 56V
Front (inflation pressure) 2.5 bar (250 kPa) (36.26 PSI)
Front (inflation pressure with passenger) 2.6 bar (260 kPa) (37.71 PSI)
Rear (size) 150 / 70B - 17 69V
Rear (inflation pressure) 2.5 bar (250 kPa) (36.26 PSI)
Rear (inflation pressure with passenger) 2.6 bar (260 kPa) (37.71 PSI)

Supply

POWER SUPPLY
Specification Desc./Quantity
Type Electronic injection (Marelli MIU G4)
Diffuser Ø 38 mm (1.50 in)
Fuel Unleaded gasoline E10 (95 R.O.N.)

Tightening Torques

Chassis

CHAR - 21
Characteristics V7 E5 Special-Stone

Front side

FRONT SUSPENSION - STEERING

Pos. Description Type Quantity Torque Notes
1 Screws fastening stanchion on upper plate M8x35 4 25 Nm (18.44 lbf ft) -
2 Steering head fastening bushing - 1 100 Nm (73.76 lb ft) -
3 Steering headstock lock nut - 1 50 Nm (36.88 lb ft) Pre-torque 60 Nm (44.25
lb ft)
4 Headstock counter-lock ring - 1 Manual -
5 Calliper bracket fixing screws M6x30 2 10 Nm (7.38 lbf ft) -

CHAR - 22
V7 E5 Special-Stone Characteristics

Pos. Description Type Quantity Torque Notes

6 Connector plate fastening screw M6x16 1 10 Nm (7.38 lbf ft) -
7 Screws fastening stanchion on lower plate M10 2 45 Nm (33.19 lb ft) -
8 Pumping unit fastening screw M10 2 50 Nm (36.88 lb ft) -

(SPECIAL)

INSTRUMENT CLUSTER
Pos. Description Type Quantity Torque Notes
1 Instrument cluster cover fastening screws Self-tap- 4 2 Nm (1.48 lb ft) -
ping
4.2x19
2 Screws fastening instrument cluster to support Self-tap- 6 2 Nm (1.48 lb ft) -
bracket ping
3.9x16
3 Support plate fastening screws M6 2 10 Nm (7.38 lbf ft) -

(STONE)

CHAR - 23
Characteristics V7 E5 Special-Stone

INSTRUMENT CLUSTER
Pos. Description Type Quantity Torque Notes
1 Instrument cluster cover fastening screws Self-tap- 2 2 Nm (1.46 lbf ft) -
ping
4.2x13
2 Screws fastening instrument cluster to support Self-tap- 3 3 Nm (2.21 lbf ft) -
bracket ping 5x14
3 Support plate fastening screws M6 2 10 Nm (7.38 lbf ft) -
4 Support plate fastening nuts M6 2 10 Nm (7.38 lbf ft) -

CHAR - 24
V7 E5 Special-Stone Characteristics

HANDLEBAR AND CONTROLS

Pos. Description Type Quantity Torque Notes
1 Screw fixing handlebar support U-bolts to M10 2 50 Nm (36.88 lb ft) -
steering plate
2 Handlebar U-bolt fastener screws M8 4 25 Nm (18.44 lbf ft) -
3 Mirror fixing M10 2 Manual -
- Light switch fastening screws SWP 5 2 1.5 Nm (1.11 lb ft) -
- Throttle cable cover fastening screws M5 3 6 Nm (4.43 lbf ft) -

FRONT BRAKE MASTER CYLINDER

Pos. Description Type Quantity Torque Notes
1 Front brake master cylinder U-bolt fixing M6 2 10 Nm (7.38 lbf ft) -
screws
2 Brake light switch fastening screws M4 1 3 Nm (2.21 lbf ft) -

(SPECIAL)

CHAR - 25
Characteristics V7 E5 Special-Stone

HEADLIGHT UNIT
Pos. Description Type Quantity Torque Notes
1 Headlamp fastening screws M8 2 15 Nm (11.10 lb ft) -
2 Front turn indicators fastening screws M6 2 5 Nm (3.69 lb ft) -
3 Screws fastening the headlight support strips M6 2 10 Nm (7.38 lbf ft) -

(STONE)

CHAR - 26
V7 E5 Special-Stone Characteristics

HEADLIGHT UNIT
Pos. Description Type Quantity Torque Notes
1 Headlamp fastening screws M8 2 15 Nm (11.10 lb ft) -
2 Front turn indicators fastening screws M6 2 5 Nm (3.69 lb ft) -
3 Screws fastening the headlight support strips M6 2 10 Nm (7.38 lbf ft) -

FRONT MUDGUARD
Pos. Description Type Quantity Torque Notes
1 Screws fastening the stabiliser plate to the fork M8 4 15 Nm (11.06 lbf ft)
2 Screw fastening the mudguard to the stabiliser M6 4 10 Nm (7.38 lbf ft)
plate

(SPECIAL)

CHAR - 27
Characteristics V7 E5 Special-Stone

FRONT WHEEL
Pos. Description Type Quantity Torque Notes
1 Wheel axle M18 1 80 Nm (59.00 lb ft) -
2 Front brake disc fixing screws M8 6 25 Nm (18.44 lbf ft) Loctite 243
3 ABS-sensor fixing stud bolt M5 1 6 Nm (4.43 lbf ft) Pre-permeated
4 Cable grommet nut M6 1 6 Nm (4.43 lbf ft) -

(STONE)

CHAR - 28
V7 E5 Special-Stone Characteristics

FRONT WHEEL
Pos. Description Type Quantity Torque Notes
1 Wheel axle M18 1 80 Nm (59.00 lb ft) -
2 Front brake disc fixing screws M8 6 25 Nm (18.44 lbf ft) Loctite 243
3 ABS-sensor fixing stud bolt M5 1 6 Nm (4.43 lbf ft) Pre-permeated
4 Cable grommet nut M6 1 6 Nm (4.43 lbf ft) -

FRONT BRAKE CALLIPER

Pos. Description Type Quantity Torque Notes
1 Screws fastening front brake calliper M10 2 50 Nm (36.88 lb ft) -

CHAR - 29
Characteristics V7 E5 Special-Stone

Central part

FRAME
Pos. Description Type Quantity Torque Notes
1 Screws fastening the tank support M8 2 25 Nm (18.44 lbf ft) -
buffers to the frame
2 Front cradle fixing screws M10 4 50 Nm (36.88 lb ft) Pre-permeated
3 Screw fastening the stand cross- M10 1 50 Nm (36.88 lb ft) Pre-permeated
piece to the cradles
4 Battery holder plate fixing screw M8 4 25 Nm (18.44 lbf ft) Pre-permeated
5 Screws fastening engine/gearbox to M10 3 50 Nm (36.88 lb ft) -
frame
6 Screws fastening gearbox to frame M10 2 50 Nm (36.88 lb ft) -
7 Rear grab handle fastening screws M6 2 10 Nm (7.38 lbf ft) -

CHAR - 30
V7 E5 Special-Stone Characteristics

FOOTRESTS
Pos. Description Type Quantity Torque Notes
1 Screws fastening rider footrest support to M8 4 25 Nm (18.44 lbf ft) Screw + nut
the frame
2 Screws fastening passenger footrest sup- M8 4 25 Nm (18.44 lbf ft) Pre-permeated
port to the frame
3 Anti-sliding pin - 2 10 Nm (7.38 lbf ft) Loctite 243
4 Footrest rubber fastening screws M6 8 10 Nm (7.38 lbf ft) -

CHAR - 31
Characteristics V7 E5 Special-Stone

GEARBOX LEVER
Pos. Description Type Quantity Torque Notes
1 Gearbox lever fixing nut M8 1 25 Nm (18.44 lbf ft) -
2 Tie-rod fastening nuts M6 3 6.5 Nm (4.78 lbf ft) -
3 Gearbox control lever fastening M6 2 10 Nm (7.38 lbf ft) -
screws
4 Gearbox lever peg fastener - 1 20 Nm (14.75 lbf ft) Loctite 243
5 Ball joint fixing M6 1 6.5 Nm (4.78 lbf ft) Loctite 243

REAR BRAKE PUMP

Pos. Description Type Quantity Torque Notes
1 Brake master cylinder reservoir fixing M6 2 10 Nm (7.38 lbf ft) -
screws
2 Brake light switch fastening - 1 5 Nm (3.69 lb ft) Loctite 243
3 Rear brake lever peg fastening - 1 20 Nm (14.75 lbf ft) Loctite 243
4 Rear brake lever fixing pin - 1 20 Nm (14.75 lbf ft) -
5 Fork fixing nut M6 1 10 Nm (7.38 lbf ft) -

CHAR - 32
V7 E5 Special-Stone Characteristics

SIDE STAND
Pos. Description Type Quantity Torque Notes
1 Side stand retainer pin M10x1.2 1 10 Nm (7.38 lbf 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 (4.43 lbf ft) -

CHAR - 33
Characteristics V7 E5 Special-Stone

FUEL TANK
Pos. Description Type Quantity Torque Notes
1 Screws fastening fuel pump to fuel tank M5 6 5 Nm (3.69 lb ft) Pre-permeated
2 Rear tank fastening screw M8 1 25 Nm (18.44 lbf ft) -

FILTER BOX
Pos. Description Type Quantity Torque Notes
1 Filter box fastening screws SWP M5 9 3 Nm (2.21 lbf ft) -
2 Air filter cover fastening screws SWP M5 4 3 Nm (2.21 lbf ft) -
3 Filter casing/frame fastening screw SWP M5 2 3 Nm (2.21 lbf ft) -

CHAR - 34
V7 E5 Special-Stone Characteristics

CENTRAL BODYWORK
Pos. Description Type Quantity Torque Notes
1 Starter motor cover fastening screws M5 2 4 Nm (2.95 lb ft) -
2 Throttle body cover fastening screws M5 4 3 Nm (2.21 lbf ft) -
3 Side panel fastening screws M5 2 4 Nm (2.95 lb ft) -

CHAR - 35
Characteristics V7 E5 Special-Stone

LOCK KIT
Pos. Description Type Quantity Torque Notes
1 (Shear head) screw fixing ignition M8 1 At the point of failure Loctite 243
lock
2 Ignition lock fixing screw M8 1 25 Nm (18.44 lbf ft) Pre-permeated
3 Saddle release block fixing screws M6 2 8 Nm (5.9 lb ft) -

EXHAUST SYSTEM
Pos. Description Type Quantity Torque Notes
1 Fastening the exhaust pipe to the en- M8 4 25 Nm (18.44 lbf ft) -
gine
2 Fastening the exhaust pipe to the si- M8 2 25 Nm (18.44 lbf ft) -
lencer
3 Lambda probes fastener M12x1.25 2 25 Nm (18.44 lbf ft) -
4 Fastening the silencers to the sup- M8 6 25 Nm (18.44 lbf ft) -
port
5 Fastening the RH/LH manifold heat M6 2 8 Nm (5.9 lb ft) -
shield
6 RH/LH manifold heat shield clamp - 2 3.5 Nm (2.58 lb ft) -
7 Fastening the RH/LH silencer heat M6 4 8 Nm (5.9 lbf ft) -
shield
8 Fastening the silencer to the support M8 4 25 Nm (18.44 lbf ft) -
on the chassis

CHAR - 36
V7 E5 Special-Stone Characteristics

ABS SYSTEM
Pos. Description Type Quantity Torque Notes
1 Control unit bracket fastening to the M6x16 2 10 Nm (7.38 lbf ft) -
frame
2 Screw fastening brake lines fasten- M4 1 3 Nm (2.21 lbf ft) -
ing plates
3 Clamp fastening screw M5 1 6 Nm (4.43 lbf ft) -

Back side

CHAR - 37
Characteristics V7 E5 Special-Stone

SWINGARM
Pos. Description Type Quantity Torque Notes
1 Pins fixing swingarm to gearbox - 2 - Manual
2 Counter-nuts fixing swingarm to - 2 50 Nm (36.88 lb ft) -
gearbox
3 Rubber bellows torx fixing screws - 3 6 Nm (4.43 lbf ft) -

BEVEL GEAR
Pos. Description Type Quantity Torque Notes
1 Pinion unit fixing nut - OPTION 01 M25 1 100 Nm (73.76 lb ft) Loct. 243
2 Pinion unit fixing lock nut - OPTION M25 1 20 Nm (14.75 lbf ft) Loct. 243
01
3 Pinion unit fixing nut - OPTION 02 M25 1 100 Nm (73.76 lb ft) Loct. 243 + Nut re-
bating on hollow
pinion
4 Oil drainage plug M10 1 30 Nm (22.13 lb ft) -
5 Oil load cap M12 1 25 Nm (18.44 lbf ft) -
6 Ring nut - 1 100 Nm (118.01 lbf ft) Loct. 243 + Riveting
on the splash guard
hub
7 Bleeder cap - 1 10 Nm (7.38 lbf ft) -
8 Gearbox cover fastening screws M8x25 8 25 Nm (18.44 lbf ft) -

CHAR - 38
V7 E5 Special-Stone Characteristics

REAR SHOCK ABSORBERS

Pos. Description Type Quantity Torque Notes
1 Rear shock absorber upper/lower fixing M6 4 10 Nm (7.38 lbf ft) Pre-permeated
screws
2 Pin fastening the shock absorber to the gear- M12 2 35 Nm (25.81 lb ft) Pre-permeated
box/swingarm

CHAR - 39
Characteristics V7 E5 Special-Stone

REAR BRAKE CALLIPER

Pos. Description Type Quantity Torque Notes
1 Rear brake calliper fixing screw M8 2 25 Nm (18.44 lbf ft) -
2 Screw fastening the calliper holder M16x1 1 35 Nm (25.81 lb ft) -
plate to the swingarm

(SPECIAL)

(STONE)

CHAR - 40
V7 E5 Special-Stone Characteristics

REAR WHEEL
Pos. Description Type Quantity Torque Notes
1 Rear brake disc fastening screws M8 6 25 Nm (18.44 lbf ft) Loctite 243
2 Rear wheel axle fastener pin + nut M20 1 100 Nm (73.77 lb ft) -
3 ABS sensor fixing screw M6 1 6 Nm (4.43 lbf ft) Loctite 243

REAR LIGHT ASSEMBLY

Pos. Description Type Quantity Torque Notes
1 Taillight to internal support fixing screws SWP 3 2 2 Nm (1.48 lb ft) -
2 Screws fastening the internal support to the SWP 3 3 2 Nm (1.48 lb ft) -
lower cover
3 Upper cover fixing screws SWP 3 3 2 Nm (1.48 lb ft) -
4 Screws fastening the taillight to the mudguard SWP 3 3 5 Nm (3.69 lb ft) -
5 Direction indicator fastening screws M6 2 5 Nm (3.69 lb ft) -
6 Licence plate light fastening screws M4 2 3 Nm (2.21 lbf ft) -
7 Screw fixing the reflector to the support M5 1 4 Nm (2.95 lb ft) -
8 Screws fastening reflector support to the plate M5 2 4 Nm (2.95 lb ft) -
holder

CHAR - 41
Characteristics V7 E5 Special-Stone

REAR MUDGUARD
Pos. Description Type Quantity Torque Notes
1 Rear mudguard fixing screws M8 2 20 Nm (14.75 lbf ft)
2 Front and centre fastening screw rear mud- M6 3 8 Nm (5.9 lb ft)
guard
3 Rear splash guard fastening screws M6 2 10 Nm (7.38 lbf ft)

CHAR - 42
V7 E5 Special-Stone Characteristics

SECONDARY AIR SYSTEM

Pos. Description Type Quantity Torque Notes
1 Red valve cover fixing SHC screws M5x16 4 3-4 Nm (2.21-2.95 lb ft) -

FRONT ELECTRICAL SYSTEM

Pos. Description Type Quantity Torque Notes
1 Voltage regulator and horn fastening screws M6 2 10 Nm (7.38 lbf ft) -
2 Clutch switch fixing screw M8 1 5 Nm (3.69 lb ft)

CHAR - 43
Characteristics V7 E5 Special-Stone

CENTRAL ELECTRICAL SYSTEM

Pos. Description Type Quantity Torque Notes
- Coils fastening nuts M6 4 10 Nm (7.38 lbf ft) -
- Starter motor fixing screws M8 2 25 Nm (18.44 lbf ft)

REAR ELECTRICAL SYSTEM

Pos. Description Type Quantity Torque Notes
- Control unit cable grommet fastening screw M4 1 3 Nm (2.21 lbf ft) Thread-form-
ing screws
- Battery holder bracket fastening screws M6 2 Manual -
- Fuse box bracket fastening screws M5 2 4 Nm (2.95 lb ft) -

CHAR - 44
INDEX OF TOPICS

SPECIAL TOOLS S-TOOLS

Special tools V7 E5 Special-Stone

SPECIAL TOOLS
Stores code Description
020998Y Pinion case wrench

020999Y Crown counter- lock ring wrench

GU19907000 Internal bearing ring extractor

021000Y Bevel gear set mounting

021003Y Bevel gear oil seal punch

021005Y Bevel gear cover oil seal punch

S-TOOLS - 46
V7 E5 Special-Stone Special tools

Stores code Description

020978Y Cardan secondary oil seal mounting
punch

GU19927900 Punch for pressing the ring inside the

bearing

020376Y Adaptor handle

020360S Adaptor 52x54 mm

001467Y036 Bearing internal cup extractor

020966Y Steering adjustment socket

020922Y Diagnostic tool

S-TOOLS - 47
Special tools V7 E5 Special-Stone

Stores code Description

021017Y OBD cable for E5 vehicles

Special tools are necessary for the correct removal and refitting and a good set-up. By using these special tools damages deriving
from the use of incorrect tools and/or improvised operations will be avoided. Here is a list of the special tools suitably designed
for this vehicle. If necessary, ask for the special tools.

SPECIAL TOOLS
Stores code Description
021009Y Engine axial clearance check tool

[Link] Punch for seal ring of bevel gear set pin-

ion

[Link] Bevel gear set alignment pre-fitting tool

[Link] Punch for gearcase sealing ring

GU19907000 Internal bearing ring extractor

S-TOOLS - 48
V7 E5 Special-Stone Special tools

Stores code Description

[Link] Extractor for external ring of gearcase
bearing

[Link] Punch for bearing on bevel gear set pin-

ion

[Link] Punch for external ring of tapered bearing

on bevel gear set pinion holding body

GU19926500 Punch for transmission case bearing ex-

ternal ring

[Link] Extractor for swinging arm holder bearing

on gearbox cover

S-TOOLS - 49
INDEX OF TOPICS

MAINTENANCE MAIN
V7 E5 Special-Stone Maintenance

Scheduled maintenance table

NOTE
HALVE THE SERVICE INTERVALS INDICATED IF THE VEHICLE IS USED IN PARTICULARLY
RAINY OR DUSTY CONDITIONS, ON POOR ROADS OR FOR HIGH PERFORMANCE RIDING.
NOTE
THE TIMES LISTED ON THE SCHEDULED MAINTENANCE TABLE INCLUDE TIME DEDICATED
TO MANAGEMENT ACTIVITIES.
I: CHECK AND CLEAN, ADJUST, LUBRICATE OR REPLACE, IF NECESSARY
C: CLEAN
R: REPLACE
A: ADJUST
L: LUBRICATE
(1): Replace in case of leaks
(2): Replace every 4 years
(3): Check every month
(4): Check every 5,000 km (3,106 miles)
(5): Check and clean, adjust or replace if necessary every 1000 km (621 miles)
(6): Replace at whichever of the following occurs first: 40,000 km (24,855 miles) or 4 years
(7): At each service (except the first one), check inside the filter box, if there is oil. Clean if necessary

SCHEDULED MAINTENANCE TABLE

Km x 1,000 (mi x 1,000) 1,5 10 20 30 40 50 60 EVERY EVERY
(0.9) (6.2) (12.4) (18.6) (24.9) (31.1) (37.3) 12 24
MONTH MONTH
S S
Oil filter cover O-ring R R R R R R R R R
Gearbox oil filler plug O-ring I I
Engine oil filler plug O-ring I I I I I I I I I
Spark plugs R R R R R R
Filter box (7) C C C C C C
Steering bearings and steering play I I I I I I I I I
Wheel bearings - Wheels I I I I I I I I
Diagnosis by tool I I I I I I I I I
Brake discs - Pads wear (5) I I I I I I I I I
Air filter R R R R R R
Engine oil filter R R R R R R R R R
Vehicle general operation I I I I I I I I I
Valve clearance A A A A A A A
Head cover gasket I I I I I I I
Gearbox oil discharge plug aluminium gas- R R
ket
Engine oil discharge plug aluminium gasket R R R R R R R R R
Transmission oil discharge plug gasket R R
Gasket for the engine oil filter fastening R R R R R R R R R
screw
Brake 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 I I I I I I I I R
Gearbox oil R R
Fork oil (6) R
Engine oil (4) R R R R R R R R R
Final drive oil R R

MAIN - 51
Maintenance V7 E5 Special-Stone

Km x 1,000 (mi x 1,000) 1,5 10 20 30 40 50 60 EVERY EVERY

(0.9) (6.2) (12.4) (18.6) (24.9) (31.1) (37.3) 12 24
MONTH MONTH
S S
Headlight aiming I I I I I I
Fork oil seals (1) I I I I I
Tyres - pressure / wear (3) I I I I I I I I I
Clutch clearance adjustment A A A A A A A A A
Transmission oil filler plug washer R R
Nut/bolt tightness I I I I I I I
Suspensions and stability I I I I I
Head cover fastening screws dampers I I I I I I I
Filter box drain plug C C C C C C C C C
Brake lines I I I I I I
Fuel lines (2) I I I I I I I I
Labour time (minutes) 80 90 90 110 120 90 110 60 60
NOTE
AT EACH SCHEDULED MAINTENANCE MUST BE VERIFIED WITH THE DIAGNOSTIC TOOL IF
THERE ARE ERRORS AND THE IF THE PARAMETERS ARE CORRECT.
ENSURE THAT THE VEHICLE CALIBRATION IS UP TO DATE AFTER UPDATING THE DIAGNOS-
TIC TOOL.

SCHEDULED MAINTENANCE TABLE RESERVED FOR THE US-LATAM MARKET

I: CONTROLLARE E PULIRE, REGOLARE, LUBRIFICARE O SOSTITUIRE SE NECESSARIO

C: PULIRE
R: SOSTITUIRE
A: REGOLARE
L: LUBRIFICARE
(1): Sostituire in caso di trafilaggi
(2): Sostituire ogni 4 anni
(3): Controllare ogni mese
(4): Verificare ogni 3.106 mi (5.000 Km)
(5): Controllare e pulire, regolare o sostituire se necessario ogni 621 mi (1.000 Km)
(6): Sostituire al raggiungimento della prima opzione tra le due seguenti: 24.855 mi (40.000 Km) oppure
4 anni
(7): Ad ogni tagliando (escluso il primo) controllare all'interno della cassa filtro se c'è presenza di olio.
In tal caso procedere alla pulizia

TABELLA DI MANUTENZIONE PROGRAMMATA

mi x 1.000 (Km x 1.000) 0.9 (1.5) 6.2 (10) 12.4 (20) 18.6 (30) 24.9 (40) 31.1 (50) 37.3 (60)
Oil filter cover O-ring R R R R R R R
Gearbox oil filler plug O-ring I I
Engine oil filler plug O-ring I I I I I I I
Spark plugs R R R R R R
Filter box (7) C C C C C C
Steering bearings and steering play I I I I I I I
Wheel bearings - Wheels I I I I I I
Diagnosis by tool I I I I I I I
Brake discs - Pads wear (5) I I I I I I I
Air filter R R R R R R
Engine oil filter R R R R R R R
Vehicle general operation I I I I I I I
Valve clearance A A A A A A A

MAIN - 52
V7 E5 Special-Stone Maintenance

mi x 1.000 (Km x 1.000) 0.9 (1.5) 6.2 (10) 12.4 (20) 18.6 (30) 24.9 (40) 31.1 (50) 37.3 (60)
Head cover gasket I I I I I I I
Gearbox oil discharge plug aluminium gasket R R
Engine oil discharge plug aluminium gasket R R R R R R R
Transmission oil discharge plug gasket R R
Gasket for the engine oil filter fastening screw R R R R R R R
Brake systems I I I I I I I
Light circuit I I I I I I I
Safety switches I I I I I I I
Brake Fluid I I I I I I I
Gearbox oil R R
Fork oil (6) R
Engine oil (4) R R R R R R R
Final drive oil R R
Headlight aiming I I I I I I
Fork oil seals (1) I I I I I
Tyres - pressure / wear (3) I I I I I I I
Clutch clearance adjustment A A A A A A A
Transmission oil filler plug washer R R
Nut/bolt tightness I I I I I I I
Suspensions and stability I I I
Head cover fastening screws dampers I I I I I I I
Filter box drain plug C C C C C C C
Brake lines I I I I I I
Fuel lines (2) I I I I I I
Labour time (minutes) 80 90 90 110 120 90 110
NOTE
AT EACH SCHEDULED MAINTENANCE MUST BE VERIFIED WITH THE DIAGNOSTIC TOOL IF
THERE ARE ERRORS AND THE IF THE PARAMETERS ARE CORRECT.
ENSURE THAT THE VEHICLE CALIBRATION IS UP TO DATE AFTER UPDATING THE DIAGNOS-
TIC TOOL.

Recommended products

Piaggio Group recommends the use of prod-

ucts from its Castrol official partner for the
scheduled maintenance of its vehicles.
Only use lubricants and fluids which meet or ex-
ceed the performance characteristics specified.
This also applies when topping up only.

TABLE OF RECOMMENDED PRODUCTS

Product Description Specifications
Engine oil 10W-60 Synthetic based lubricant for high per- SAE 10W 60; JASO MA, MA2; API SG
formance four-stroke engines.
75W-140 lubricant for gearboxes and Synthetic lubricant for gearboxes and SAE 75W-140 - API GL5
transmissions transmissions
Fork oil 7.5W Fork oil. SAE 7.5W
Molybdenum disulphide grease Lithium grease with molybdenum disul- Grey black grease.
phide
Vaseline neutral grease for battery terminals -
Brake fluid DOT 4 Synthetic brake fluid. SAE J 1703; FMVSS 116; ISO 4925; CU-
NA NC 956 DOT4

Transmission fluid

MAIN - 53
Maintenance V7 E5 Special-Stone

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 recipient with a capacity of at
least 400 cc (25 [Link]) under the drain
plug (2).
• Unscrew and remove the drainage
plug (2).
• Unscrew and remove the filler plug (1).
• Drain the oil into the container for at
least 5 minutes for oil to drain out com-
pletely.
• Replace the sealing washer of the dis-
charge plug (2).
• Remove any metal scrap attached to
the drainage plug (2) magnet.
• Screw and tighten the drainage plug
(2).
• Fill with new oil via the inlet hole.
• Quantity 160 cc MAX (9.76 cu in) (filling
amount after emptying; - 20 cc (1.22 cu
in) compared to the nominal amount of
180 cc (10.98 cu in), to compensate for
the oil residue remaining in the gear-
case).
CAUTION
DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO
THE FLUID. WHEN USING A FUNNEL OR ANY OTHER EL-
EMENT, MAKE SURE IT IS PERFECTLY CLEAN.
NOTE
THE RECOMMENDED QUANTITY OF OIL FOR REPLACE-
MENT IS 160 cc (9.76 cu in)

Recommended products
75W-140 lubricant for gearboxes and transmis-
sions Synthetic lubricant for gearboxes and
transmissions
SAE 75W-140 - API GL5
• Screw and tighten the cap (1).
NOTE
WHILE REFITTING, USE A NEW SEAL WASHER.

MAIN - 54
V7 E5 Special-Stone Maintenance

CAUTION
IF IT IS NECESSARY TO INSTALL A NEW TRANSMISSION GEARBOX, PAY SPECIAL ATTEN-
TION TO THE PROCEDURE BELOW
Since they are already run-in at the factory, the complete transmission boxes coming from the Spare
parts department contain a minimum residual oil quantity and therefore after installing them on the
vehicle, the following procedure must be performed:

• Open the filler plug and drain any residual oil from the lower drain plug leaving it to drip for
at least 5 minutes.
• Refit and tighten the lower drain plug and refill through the filler plug with 160 cu cm (9.76
cu in) of oil.
• Refit and tighten the filler plug.
• Assemble the breather plug. If the gearbox arrived with the breather plug already assembled,
remove it and blow it with compressed air to carefully remove any oil residues.
CAUTION
WHILE REFITTING, USE A NEW SEAL WASHER FOR THE BREATHER CAP.

Engine oil

Check

Check the engine oil level frequently.

NOTE
HALVE THE SERVICE INTERVALS INDICATED IF THE VEHICLE IS USED IN PARTICULARLY
RAINY OR DUSTY CONDITIONS, ON POOR ROADS OR FOR HIGH PERFORMANCE RIDING.

THE OIL LEVEL MUST BE CHECKED WHEN THE ENGINE IS WARM.

CAUTION
DO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT A STANDSTILL TO WARM UP THE
ENGINE AND OBTAIN THE OPERATING TEMPERATURE OF ENGINE OIL.
PREFERABLY CHECK THE OIL AFTER A JOURNEY OF AFTER TRAVELLING APPROXIMATELY
15 Km (10 miles) IN EXTRA-URBAN CONDITIONS (ENOUGH TO WARM UP THE ENGINE OIL TO
OPERATING TEMPERATURE).
• Shut off the engine.
• Keep the vehicle upright with both
wheels on the earth.
• Using the relative opening on the en-
gine casing, check the oil level.

MAX (top notch) = maximum level.

MIN (bottom notch) = minimum level

• The level is correct if it reaches the

"MAX" level.

MAIN - 55
Maintenance V7 E5 Special-Stone

Replacement
NOTE
HOT OIL IS MORE FLUID AND WILL DRAIN OUT MORE EASILY AND COMPLETELY.
• Posizionare un contenitore con capac-
ità di raccolta adeguata in corrispon-
denza del tappo di scarico (1)
• Svitare e togliere il tappo di scarico (1)
NOTE
WHILE REFITTING, USE A NEW SEAL WASHER.

• Unscrew and remove the filler plug (2)

• Drain the oil into the container; allow
several minutes for oil to drain out com-
pletely.
• Check and if necessary, replace the
sealing washer of drainage plug (1).
• Remove any metal deposits attached
to the drainage plug (1) magnet.
• Screw and tighten the drainage plug
(1).
CAUTION
CHECK THE O-RING PRESENT ON THE FILLING CAP AND
REPLACE IF DAMAGED.

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 - 56
V7 E5 Special-Stone Maintenance

Engine oil filter

• Undo the two screws (1) and remove

the cover (2)
• Remove the engine oil filter (3)
• Spread a thin layer of oil on the sealing
ring of the new engine oil filter
• Fit the new engine oil filter with the
spring facing downwards
• Refit the cover (2), screw and tighten
the screw (1)
NOTE
NEVER REUSE AN OLD FILTER.
NOTE
WHILE REFITTING, USE A NEW SEAL WASHER.
NOTE
WHILE REFITTING, USE A NEW SEAL O-RING.

Gearbox Oil

Replacement
NOTE
HOT OIL IS MORE FLUID AND WILL DRAIN OUT MORE EASILY AND COMPLETELY.
• Place a container with suitable capaci-
ty under the drainage plug (2).
• Unscrew and remove the drainage
plug (2).

• Unscrew and remove the filler plug (1).

• 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 plug (2).
• Remove any metal scrap attached to
the drainage plug (2) magnet.

MAIN - 57
Maintenance V7 E5 Special-Stone

• Remove the air filter (3) and clean it

• Check the O-Ring (4) and if necessary
replace it
• Screw and tighten the drainage plug
(2)

• Pour in new oil, observing the quantity indicated in the table "capacity"
• Tighten the filler cap (1).
CAUTION
DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO THE FLUID. WHEN USING A FUNNEL
OR ANY OTHER ELEMENT, MAKE SURE IT IS PERFECTLY CLEAN.

Air filter

• Remove the saddle

• Unhook the connector from the air-box
cover

• Remove the air-box cover fixing screw

MAIN - 58
V7 E5 Special-Stone Maintenance

• Remove the air-box cover

• Extract the air filter

Throttle body removal

• Remove the clip clamp fixing the

sleeve to the filter box
CAUTION
DURING REFITTING, REPLACE THE CLIP CLAMP

• Loosen the clamps that secure the sleeve to the intake manifolds

• Remove the sleeve

MAIN - 59
Maintenance V7 E5 Special-Stone

• Remove the battery

• Remove the MIU G4 control unit con-
nector support bracket fixing screw

• Disconnect the MIU G4 control unit

connector

• Remove the clip clamp fixing the throt-

tle body to the filter box
• Extract the throttle body laterally

• Remove the throttle body guard

MAIN - 60
V7 E5 Special-Stone Maintenance

• Loosen the gas cables fixing nuts on

the throttle body and unhook them

• Remove the throttle body

Air filter housing

FILTER BOX
Pos. Description Type Quantity Torque Notes
1 Filter box fastening screws SWP M5 9 3 Nm (2.21 lbf ft) -
2 Air filter cover fastening screws SWP M5 4 3 Nm (2.21 lbf ft) -

MAIN - 61
Maintenance V7 E5 Special-Stone

Pos. Description Type Quantity Torque Notes

3 Filter casing/frame fastening screw SWP M5 2 3 Nm (2.21 lbf ft) -

Air filter housing removal

• Remove the saddle and the side fair-

ings
• Remove the battery
• Remove the rear wheel.
• Remove the splash guard
• Remove the fuse box support fixing
screws (1)

• Move the filter box to the side enough

to allow removal of the fixing screws (2)
on the left side of the filter box support.

• Move the filter box to the side enough

to allow removal of the fixing screws (3)
on the right side of the filter box sup-
port.

• Disconnect the neutral switch connec-

tor
• Lift the air filter box enough to allow the
support plate to be removed, sliding
out neutral switch cabling

MAIN - 62
V7 E5 Special-Stone Maintenance

• Unscrew the clamp that fastens the

throttle body to the air filter box

• Disconnect the blow-by pipe

• Remove the air-box cover

• Remove sliding the complete filter box

out toward the rear

MAIN - 63
Maintenance V7 E5 Special-Stone

Air filter housing installation

• Insert the filter box from the rear

• Insert the throttle body in the sleeve

and tighten the clamp to secure it
CAUTION
TAKE PARTICULAR CARE THAT THE CLAMP IS POSI-
TIONED CORRECTLY. INCORRECT POSITIONING WILL
CAUSE VEHICLE MALFUNCTIONS

• Install the air-box cover

• Connect the blow-by and breather

tubes

MAIN - 64
V7 E5 Special-Stone Maintenance

• Position the air filter box support, tak-

ing car to pass the neutral switch ca-
bling through the hole

• Move the filter box to the side enough

to allow tightening of the fixing screws
(3) on the right side of the filter box
support.

• Move the filter box to the side enough

to allow tightening of the fixing screws
(2) on the left side of the filter box sup-
port.

• Correctly position the air filter box on

the support
• Fix the screws (1) of the fuse box sup-
port

MAIN - 65
Maintenance V7 E5 Special-Stone

Checking the valve clearance

• First, check the valve clearance in the

left cylinder, then remove the four fixing
screws (1) on the spark plug cover (2)

• Remove the spark plug cover (2)

• Disconnect the spark plug cap (3)

• Unscrew and remove the two spark

plug support retaining screws (4)

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V7 E5 Special-Stone Maintenance

• Retrieve the two spacers (5)

• Push the spark plug cable complete
with support, as indicated in the figure,
towards the front of the vehicle

• Unscrew and remove the three head

cover retaining screws (6)

• Remove the head cover (7)

• Unscrew the spark plug (8) and re-

move it

REMOVE THE RIGHT HAND CYLINDER

SPARK PLUG TOO SO THAT IT IS POSSIBLE
TO TURN THE ENGINE OVER MANUALLY, EN-
GAGE FIRST GEAR AND ROTATE THE REAR
WHEEL

• Stop rotating when the top dead centre

point is reached and check that there
is enough clearance on the rockers to
perform the measurement

MAIN - 67
Maintenance V7 E5 Special-Stone

• Use a feeler gauge to check that the

clearance between the valve and the
set screw corresponds with the indica-
ted values. The corresponding intake
and outlet valve clearances are differ-
ent than what is indicated below, pro-
ceed with adjusting them.

Characteristic
Intake valve clearance
0.10 mm (0.0039 in)
Exhaust valve clearance
0.15 mm (0.0059 in)
• Loosen the lock nut, adjust the clear-
ance by acting on the adjuster until
reaching the prescribed values
• Tighten the lock nut
• To perform the valve clearance of the
right cylinder, it is necessary to bring
the cylinder to the top dead centre, ro-
tating the engine 270 degree

Braking system

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V7 E5 Special-Stone Maintenance

FRONT BRAKE CALLIPER

Pos. Description Type Quantity Torque Notes
1 Screws fastening front brake calliper M10 2 50 Nm (36.88 lb ft) -

FRONT BRAKE MASTER CYLINDER

Pos. Description Type Quantity Torque Notes
1 Front brake master cylinder U-bolt fixing M6 2 10 Nm (7.38 lbf ft) -
screws
2 Brake light switch fastening screws M4 1 3 Nm (2.21 lbf ft) -

MAIN - 69
Maintenance V7 E5 Special-Stone

REAR BRAKE CALLIPER

Pos. Description Type Quantity Torque Notes
1 Rear brake calliper fixing screw M8 2 25 Nm (18.44 lbf ft) -
2 Screw fastening the calliper holder M16x1 1 35 Nm (25.81 lb ft) -
plate to the swingarm

REAR BRAKE PUMP

Pos. Description Type Quantity Torque Notes
1 Brake master cylinder reservoir fixing M6 2 10 Nm (7.38 lbf ft) -
screws
2 Brake light switch fastening - 1 5 Nm (3.69 lb ft) Loctite 243
3 Rear brake lever peg fastening - 1 20 Nm (14.75 lbf ft) Loctite 243
4 Rear brake lever fixing pin - 1 20 Nm (14.75 lbf ft) -
5 Fork fixing nut M6 1 10 Nm (7.38 lbf ft) -

Level check

FRONT BRAKE
CHECK

• Rest the vehicle on its stand

• Turn the handlebar so that the fluid is
at the same level as the plug.
• Check that the fluid contained in the
tank (1) exceeds the 'MIN' level refer-
ence mark

MIN = minimum level

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V7 E5 Special-Stone Maintenance

If the fluid does not reach at least the "MIN" refer-

ence mark:
CAUTION
FLUID LEVEL DECREASES GRADUALLY AS BRAKE
PADS WEAR DOWN.

• Check the brake pads and discs for wear.

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

(SPECIAL/STONE/ANNIVERSARIO)

REAR BRAKE
CHECK

• Keep the vehicle upright so that the flu-

id in the reservoir is at the same level
as the plug.
• Make sure that the fluid level in the res-
ervoir is above the "MIN" reference
mark:.

MIN = minimum level

If the fluid does not reach at least the "MIN" refer-
ence mark:
CAUTION
FLUID LEVEL DECREASES GRADUALLY AS BRAKE
PADS WEAR DOWN.

• Check the brake pads and discs for wear.

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

Top-up

FRONT BRAKE

• Unscrew and remove the two fastening

screws (1) on the brake fluid reservoir
cover (2).

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Maintenance V7 E5 Special-Stone

• Remove the brake fluid reservoir cover

(2)

• Remove the inner cover (3)

• Remove the diaphragm (4)

• Top up the brake fluid reservoir

(SPECIAL/STONE/ANNIVERSARIO)

REAR BRAKE

• Unscrew and remove the two fastening

screws (1) on the brake fluid reservoir
cover (2).

MAIN - 72
V7 E5 Special-Stone Maintenance

• Remove the brake fluid reservoir cover

(2)

• Remove the inner cover (3)

• Remove the diaphragm (4)

• Top up the brake fluid reservoir

MAIN - 73
INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

V7 E5 Special-Stone Electrical system

FRONT ELECTRICAL SYSTEM

Pos. Description Type Quantity Torque Notes
1 Voltage regulator and horn fastening screws M6 2 10 Nm (7.38 lbf ft) -
2 Clutch switch fixing screw M8 1 5 Nm (3.69 lb ft)

CENTRAL ELECTRICAL SYSTEM

Pos. Description Type Quantity Torque Notes
- Coils fastening nuts M6 4 10 Nm (7.38 lbf ft) -
- Starter motor fixing screws M8 2 25 Nm (18.44 lbf ft)

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Electrical system V7 E5 Special-Stone

REAR ELECTRICAL SYSTEM

Pos. Description Type Quantity Torque Notes
- Control unit cable grommet fastening screw M4 1 3 Nm (2.21 lbf ft) Thread-form-
ing screws
- Battery holder bracket fastening screws M6 2 Manual -
- Fuse box bracket fastening screws M5 2 4 Nm (2.95 lb ft) -

ELE SYS - 76
V7 E5 Special-Stone Electrical system

Components arrangement

Key:

1. Instrument cluster
2. Coil
3. Fuel pump
4. Injector

ELE SYS - 77
Electrical system V7 E5 Special-Stone

5. Taillight
6. MIU G4 control unit
7. Engine speed sensor
8. Starter motor
9. Engine speed sensor
[Link]
[Link]
[Link] temperature sensor
[Link] cluster air sensor
[Link]
[Link] regulator
[Link]
[Link] pressure sensor
[Link] probes

Electrical system installation

INTRODUCTION
Scope and applicability
The position of the wiring harnesses, how they are fixed to the motorcycle and potential problems are
defined on the following sections in order to reach the objectives of vehicle reliability.
Materials used and corresponding quantities
The electrical system consists of the following wiring harnesses and parts:

• 1 Vehicle wiring harness

• 1 Taillight Cable harness
• 2 ABS speed sensor
• 1 Horn
• 2 Lambda probe
• 1 Stand switch
• 1 Fall sensor (grey connector)

Small parts and mountings

• 10 large black clamps

• 10 medium black clamps
• 1 Small cable guide rubber clamp
• 2 Large cable guide rubber clamps
• 1 metal clamp on the ECU
• 2 AMP connector supports
• 1 Cable grommet clamp

ELE SYS - 78
V7 E5 Special-Stone Electrical system

• 1 Black sheath
• 7 ABS Cable grommets
• 1 connector clip

Motorcycle division
The wiring harnesses on the vehicle are subdivi-
ded into three main sections, as indicated in the
figure.

1. Front of vehicle
2. Centre of vehicle
3. Rear section

SPECIAL CHECKS FOR THE CORRECT CONNECTION AND ROUTING OF CABLES

It is extremely important that any security-locks for the following connectors are properly con-
nected and correctly tightened to ensure proper engine, and therefore proper vehicle, operation.
Carry out the checks listed below.

• Instrument panel connector (is engaged and the boot well inserted)
• Rear and front wheel ABS sensor connector
• Check the correct connection of the ABS ECU connector
• Taillight connector
• Right and Left light switch connectors
• Clutch connector
• Ignition switch connector (check that the cable is not live)
• ECU connector (G4) and the correct insertion of the relative rubber plug
• Check the correct fastening of metallic bracket screw on the throttle body
• Check the correct passage and fixing of the ABS fuse
• Check the right and left injectors connection
• Check the connection of the engine head temperature sensor
• Check the insertion of the starter motor faston
• Check the correct insertion of H.V. Cables with the Coils (RH and LH).
• Check whether the Grey H.V. Cable connects on the Coil with the Grey tape
• Check whether the Grey H.V. Cable goes to the Left engine head
• Check the coils connection (and their correct positioning on the frame)
• Check ground fastening on the engine
• Check NEUTRAL cable fastening
• Check whether the right lambda probe is connected to the output labelled "RH LAMBDA"
• Check the Regulator and Flywheel connection
• Check the Pick Up connection

ELE SYS - 79
Electrical system V7 E5 Special-Stone

• Check correct insertion of the starter motor hood and engine start faston
• Check the presence of the Red protective hood on the battery Positive
• Check that the stand switch connector is blue
• Check the side stand connection and the left lambda
• Check the rear stop connection
• Check the stand switch cable ties on the frame under the vehicle
• Check the assembly of the fall sensor (if the arrow is upward and the connector is grey)
• Check the connection of the secondary air valve and the correct positioning of the cap
• Check the connection of the front stop faston
• Check the connection of the purge valve
CAUTION

THE ENCIRCLED CONNECTORS ARE CONSIDERED CRITICAL IN COMPARISON WITH ANY

OTHER BECAUSE THE VEHICLE WILL STOP OR PRESENT A MALFUNCTION IF THEY ARE AC-
CIDENTALLY DISCONNECTED.
Undoubtedly the connection of the rest of connectors is also important and essential for the
correct operation of the vehicle. It is also important and essential that the instructions regarding
the routing and fixing of the wiring harness in the various areas are followed meticulously in
order to guarantee functionality and reliability
COMPONENTS PRE-FITTING
TABLE A - ENGINE

• Check that the HV cable of the left cyl-

inder has grey taping

TABLE B - REAR COIL ON THE FRAME

• Check that the coil in this position has the connector (wiring harness side) with two contacts

ELE SYS - 80
V7 E5 Special-Stone Electrical system

TABLE C - CONDUIT

• Check that the fall sensor arrow is up-

wards and that the connector is grey

• Place a large clamp so that the sensor

cable is positioned as indicated

• Insert the regulator and horn connec-

tors from top to bottom in the hole cre-
ated between the conduit and the
chassis.

ELE SYS - 81
Electrical system V7 E5 Special-Stone

Front side

TABLE A - FRONT WHEEL ABS SENSOR PAS-

SAGE
1. Front ABS sensor
2. Cable grommet

• Pass the front ABS sensor wiring har-

ness through the cable grommet as
indicated.

• Connect the front ABS sensor wiring harness with the brake pipe using cable guides (3)

ELE SYS - 82
V7 E5 Special-Stone Electrical system

• Pass the ABS sensor wiring harness

around the steering headstock through
the metal cable grommet (4) on the
chassis and then fasten it with 2 plastic
clamps in the dedicated seat on the
conduit.

• Insert the wiring harness in the chassis

"compartment" (under the coils) and
then connect the ABS sensor wiring
harness to the wiring harness of the
vehicle. Insert the connector in the
dedicated fastener clip (5).

TABLE B - LIGHTS SWITCH CABLE PASSAGE ON THE HANDLEBAR (STONE)

• Fasten the RH light switch wiring harness on the front brake pipe using the cable guide (1)
• Using the cable guide (2), fasten the LH light switch and the clutch switch wiring harness to
the clutch cable

ELE SYS - 83
Electrical system V7 E5 Special-Stone

TABLE B1

• Check that the front stop fastons are

well fastened, by slightly pulling them

TABLE B2 - LIGHT SWITCH CABLE PASSAGE

ON THE HANDLEBAR (SPECIAL)

• Fasten the RH light switch wiring har-

ness on the front brake pipe using the
cable guide (1)
• Using the cable guide (2), fasten the
LH light switch and the clutch switch
wiring harness to the clutch cable

ELE SYS - 84
V7 E5 Special-Stone Electrical system

TABLE C - INSTRUMENT CLUSTER

1. Connector support bracket

2. Air temperature sensor connector
3. Connector support
4. Large clamp

• The large sized clamp fastens the air

temperature sensor connector and the
main branch of the instrument cluster
to one of the ignition switch assembly
fasteners

TABLE C1 - INSTRUMENT CLUSTER

• Connect the connector (5) of the main

wiring harness branch to the instru-
ment cluster. Using a small plastic
clamp, fasten the air temperature sen-
sor (6) to the instrument cluster support
bracket.

TABLE C2 - INSTRUMENT CLUSTER (STONE)

• Once fully assembled, the instrument

cluster appears as shown in the figure

TABLE C3 - INSTRUMENT CLUSTER (SPE-

CIAL)

1. Medium sized clamp

2. Small clamp
3. Air temperature sensor

ELE SYS - 85
Electrical system V7 E5 Special-Stone

TABLE C4 - INSTRUMENT CLUSTER (SPE-

CIAL)

• Once fully assembled, the instrument

cluster appears as shown in the figure

TABLE D - CABLE RUN ON THE STEERING HEADSTOCK

1. Medium sized clamp

2. Small sized clamps

• The throttle cables must be passed through the metal cable grommet on the chassis and
fastened to the wiring harnesses using a medium clamp (1)

ELE SYS - 86
V7 E5 Special-Stone Electrical system

TABLE E - INSTRUMENT CLUSTER AND

FRONT ARROWS (STONE)

• Proceed as indicated in the figure: us-

ing a small clamp, fasten both arrow
wiring harnesses to the instrument
cluster, next to the red strip on the left
arrow

TABLE E1 - INSTRUMENT CLUSTER AND

FRONT ARROWS (SPECIAL)

• Proceed as indicated in the figure

TABLE F - CLUTCH SWITCH

• Using the cable guide (1), fasten the

clutch and the LH light switch wiring
harness to the clutch cable

ELE SYS - 87
Electrical system V7 E5 Special-Stone

TABLE F1

• Pass the clutch cable wiring harness

through the metal cable grommet on
the chassis, fasten it with a large plastic
clamp to the wiring harnesses along
the steering headstock and hide the
connection behind it

TABLE G - IGNITION UNIT

• Pass the ignition unit wiring harness

through the metal cable grommet (1)
on the chassis, then fasten it with 2
plastic clamps to the dedicated com-
partment on the conduit
• Connect the wiring harness to the con-
nector 2 on the vehicle

TABLE G1

• Fit the connectors on the ignition unit

behind the steering headstock plates

ELE SYS - 88
V7 E5 Special-Stone Electrical system

Central part

TABLE A - CONDUIT ON THE FRAME

• Check that the relays are well inserted.

The quantities vary depending on the
models: Special 3 relays - Stone 2 re-
lays
• Fasten the lower part of the conduit us-
ing a large clamp (2)

TABLE A1

• Pass the connector of the voltage reg-

ulator (1) and the horn connector (2) in
the hole created by the conduit with the
frame at the bottom, to facilitate their
connection

ELE SYS - 89
Electrical system V7 E5 Special-Stone

TABLE A2

• Voltage regulator connector (1)

• RH light switch connector (2)
• LH light switch connector (3)
• RH Lambda probe connector (4)
• Front ABS sensor connector (5)

TABLE A3

• Heated handgrips provision (1)

• RH cylinder coil (2)
• Key connector (3)
• Fuel pump connector (4)
• LH Lambda sensor connector (5)

TABLE A4

• Check that the PICK UP (1) connector

is well connected

TABLE A5

• Check that the engine head (1) tem-

perature sensor connector located on
the left cylinder is well connected
• The wiring harness must pass between
the intake manifolds, as shown in the
figure

ELE SYS - 90
V7 E5 Special-Stone Electrical system

TABLE B - COIL AND LEFT CYLINDER CON-

NECTION

• Check that the HV cable with grey mark

(left engine head) is well inserted in the
coil with grey mark on the connector

TABLE C - COIL AND RIGHT CYLINDER CON-

NECTION

• Check that the HV cable without grey

mark (right engine head) is well inser-
ted in the front coil

TABLE D - PROCEDURE FOR CORRECTLY FITTING THE ABS CONTROL UNIT CONNECTOR

• The initial position of the connector fastener lever must be as shown in the figure

TABLE D1

• Place the connector on the opposite

side of the control unit and lower the
driving lever until the "click" that signals
the end of the stroke is heard.

ELE SYS - 91
Electrical system V7 E5 Special-Stone

TABLE D2

• When the connector is fully inserted,

the distance between the connector
and the ABS control unit must be 7.5
mm (0.29 in)

TABLE D3

• If the initial position of the connector

and driving lever is not as the one
shown in "TABLE D". The connector
will not be coupled correctly and the
measured distance will by greater, ap-
proximately 12 mm (0.47 in). In this
case, repeat the operations according
to the instructions in "TABLES D1/D2".
It is recommended to create a template
to check the correct insertion of the
connector.

TABLE D4

• Place the ABS ECU wiring harness as

shown in the figure

ELE SYS - 92
V7 E5 Special-Stone Electrical system

TABLE D5

• Fit the bracket (1) that connects the

ECU to the associated support using
the three fixing screws (2)

TABLE E - RH LAMBDA SENSOR

• Pass the wiring harness between the

brake pipes and the chassis and then
connect it to the connector (1) fastened
to the chassis

ELE SYS - 93
Electrical system V7 E5 Special-Stone

TABLE F - LEFT LAMBDA PROBE

• Connect the wiring harness to the con-

nector (1) fastened to the chassis

TABLE G - HORN AND REGULATOR

1. Voltage regulator
2. Horn

• The regulator's cable must pass be-

hind the frame bracket

ELE SYS - 94
V7 E5 Special-Stone Electrical system

TABLE G1

• Check the connection of the flywheel

white connector and regulator's black
connector that must have a safety
clamp to avoid disconnection
• Once connected, the connectors must
be placed behind the steering head-
stock plates and above the main wiring
harness conduit.

TABLE G2

• Operating on the left side and using a

medium clamp, fasten the regulator's
cable to the regulator's support plate
• Operating on the right side and using a
medium clamp, fasten the regulator's
and pick up's cable to the support plate

ELE SYS - 95
Electrical system V7 E5 Special-Stone

TABLE H - FLYWHEEL CABLES PASSAGE

• Using a medium clamp, fasten the fly-

wheel cable and the regulator cable to
the voltage regulator support bracket

TABLE I - NEUTRAL SENSOR CABLES PAS-

SAGE

• The wiring harness (1) of the neutral

sensor must pass through the filter box
support and in the cable guide (2)

ELE SYS - 96
V7 E5 Special-Stone Electrical system

TABLE I2

• Connect the neutral sensor cable to the

associated connector on the vehicle.
Using a small clamp, fasten the cable
to the rear cables of the ABS and Stop
sensor

TABLE A - OIL PRESSURE SENSOR

• Connect the cable to the oil pressure

sensor (1) and orient it as shown in the
picture
• Pass the sensor cable behind the
brake pipes and then fasten the cable
and the pipes to the chassis using the
metal tab on the chassis

ELE SYS - 97
Electrical system V7 E5 Special-Stone

TABLE A - OIL PRESSURE SENSOR

• Connect the cable to the oil pressure

sensor (1) and orient it as shown in the
picture
• Pass the sensor cable behind the
brake pipes and then fasten the cable
and the pipes to the chassis using the
metal tab on the chassis

TABLE K - INJECTORS

• Check the correct connection of the

right injector (1) and left injector (2) wir-
ing harness

ELE SYS - 98
V7 E5 Special-Stone Electrical system

TABLE L - SECONDARY AIR VALVE

• Check the correct connection of the

secondary air valve sensor (1) and
then apply the protective cap on the
connector

TABLE M - ANTI-THEFT FITTING

• Check the correct connection of the ig-

nition bridge (1) to the anti-theft wiring
harness on the vehicle

TABLE N - POSITIONING OF THE HEATED

HANDGRIPS FITTING

• Place the connector of the heated

handgrips wiring harness between the
chassis plates, behind the steering
headstock

ELE SYS - 99
Electrical system V7 E5 Special-Stone

TABLE O - REAR STOP SWITCH WIRING HAR-

NESS PASSAGE

• Pass the wiring harness under the

brake pipe coupling, behind the pump
and then insert it between the chassis
and the gearbox
• Fasten the wiring harness to the cable
guide (1) located on the chassis

TABLE O1

• Pass the wiring harness behind the

cardan shaft output and then fasten it
to the cable guide that was previously
fitted on the engine, behind the clutch
actuator

TABLE O2

• Connect the wiring harness to the con-

nector (2) on the vehicle
• Using a small clamp, fasten the rear
stop wiring harness to the other wiring
harnesses in the area

ELE SYS - 100

V7 E5 Special-Stone Electrical system

TABLE P - ENGINE BATTERY GROUND

• An incorrect fastening of the fixing

screws of the engine battery ground
eyelet may cause the vehicle to catch
fire
• Check the tightening to the prescribed
torque

TABLE Q - SIDE STAND SENSOR

• Using a small clamp, fasten the wiring

harness of the side stand switch, as in-
dicated

TABLE Q1

• Using a medium clamp, fasten the wir-

ing harness of the side stand switch to
the frame

ELE SYS - 101

Electrical system V7 E5 Special-Stone

TABLE Q2

• Proceed as shown in the figure, mak-

ing sure to pass the switch wiring har-
ness behind the MIU G4 ECU

TABLE Q3

• Using a plastic clamp, fasten the wiring

harness to the canister valve pipe and
connect it to the wiring harness on the
vehicle

ELE SYS - 102

V7 E5 Special-Stone Electrical system

TABLE R - ROUTING THE CABLES IN THE FIL-

TER BOX/UNDER-SEAT AREA

• The main wiring harness must pass

under the central beam of the frame

TABLE R1

• The layout of the main wiring harness

and of the various branches in the filter
box area must be as illustrated in the
image

TABLE S - MAIN FUSES AND ABS

1. Fuse "A" (10A)
2. Fuse "B" (7.5A)
3. Fuse "C" (15A)
4. Fuse "D" (5A)
5. Fuse "E" (5A)
6. Fuse "F" (30A)
7. Fuse "G" (20A)

TABLE T - PASSAGE OF THE STARTER MO-

TOR BATTERY

• The cap of the battery positive (1) must

be red
• The cable that goes from the battery
positive to the fuse box must be cov-
ered with sheath (2) and the terminal
must be covered with heat shrink ma-
terial (3)

ELE SYS - 103

Electrical system V7 E5 Special-Stone

INCORRECT SECURING OF THIS COMPONENT MAY

CAUSE THE VEHICLE TO CATCH FIRE

TABLE T1

• The starter motor cable must pass un-

der the filter box pipe

TABLE T2

• Check that the starter positive cap is

correctly inserted and that the nut is
fastened to the prescribed toque

INCORRECT SECURING OF THIS COMPONENT MAY

CAUSE THE VEHICLE TO CATCH FIRE

TABLE T3

• Check that the faston is correctly in-

serted

TABLE T4

• The protection cap may remain outside

for maximum 2-3 mm (0.078-0.118 in)

ELE SYS - 104

V7 E5 Special-Stone Electrical system

TABLE U - OBD 2 PORT

• Insert the plug (1) in the OBD 2 port

and then insert the port in the associ-
ated rubber support, located next to the
fuse box

TABLE V - USB PORT FITTING

• Place the wiring harness as shown in

the figure and then insert the USB port
fitting in its coupling on the air filter box

TABLE W - GMP FITTING

• Make sure that the plug of the fitting

connector is correctly inserted
• Insert the GMP fitting connector be-
tween the rear mudguard and the air
filter box

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TABLE X - MIU G4 ECU

• The MIU G4 ECU wiring harness

branch must be placed as shown in the
figure
• Make sure that the connector's rubber
protection is well fitted

TABLE X1

• With the rubber protection well fitted on

the connector, fasten it to the wiring
harness branch with the bracket (1)
• Tighten the screw (2) to the prescribed
torque and fasten the wiring harness to
the conduit using a plastic clamp

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TABLE Y - CANISTER VALVE

• Proceed as indicated in the figure

• Make sure that the canister valve is
positioned as in the figure so as to have
the connection perpendicular to the
support bracket

Back side

TABLE A - REAR WHEEL ABS SENSOR ROUT-

ING

• Pass the ABS sensor cable behind the

brake calliper coupling
• Using a cable guide (1), fasten the ABS
sensor cable to the rear brake pipe

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TABLE A1

• Using the two small clamps, fasten the

ABS sensor cable to the rear brake
pipe
• Pass the cable through the space be-
tween the gearbox and the swingarm,
next to the cardan shaft output

TABLE A2

• Connect the ABS sensor cable to the

connector (1) on the vehicle
• Using a small clamp, fasten to the can-
ister valve pipe the ABS sensor cable
together with the other cables in the
area

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TABLE B - TAILLIGHTS AND REAR ARROWS

• Fasten the wiring harness through the

cable grommet (1), next to the grey ref-
erence mark on it
• Connect the connectors of the follow-
ing: taillight (2), left arrow (3) and right
arrow (4)
NOTE
The right arrow cables are marked with RED taping

TABLE B1

• Fit the upper case on the taillight and

tighten the three fixing screws (5)
• Make sure to avoid damaging the ar-
row cables while fitting the upper case

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TABLE C - LICENSE PLATE LIGHT

• Install the licence plate light on the

plate holder

TABLE D - REAR MUDGUARD PRE-FITTING

• Fit the taillight on the mudguard, mak-

ing sure to apply the cable grommet
rubber seal (1) correctly, as shown in
the figure

TABLE D1

• Fasten the taillight wiring harness

through the cable grommet (2), using
one of the screws used to fasten the
taillight to the mudguard

TABLE D2

• Fit the licence plate holder on the rear

mudguard and then connect the li-
cence plate light to the connector (3) on
the taillight wiring harness

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TABLE D3

• Spread the cable as shown in the fig-

ure, making sure to insert it in the spe-
cific places inside the mudguard
• Fit the screws (4) and the washer until
the end, to prevent the cable from be-
coming loose from its seat

TABLE D4

• Fit the lower latch on the mudguard

• Pass the cable through the hole on the
rear side of the mudguard and then
fasten the cable using a small clamp

General wiring diagram

(HALOGEN)

(SPECIAL)

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Key:

1. Multiple connectors
2. air temperature sensor
3. Instrument cluster
4. Instrument cluster
5. Lights relay
6. Starter motor relay

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7. Clutch switch
8. Right light switch
9. Front stop switch
[Link]
[Link] light switch
[Link] socket (where applicable)
[Link] light switch
[Link] switch
[Link] right turn indicator (LED)
[Link] (LED)
[Link] plate light (LED)
[Link] left turn indicator (LED)
[Link] (R=220 ohm 3W)
[Link] with the bridge
[Link]-theft (if fitted)
[Link]-theft led (if fitted)
[Link] control unit
[Link] ABS sensor
[Link] ABS sensor
[Link] fuse
[Link]
[Link]
[Link]
[Link]
[Link] motor
[Link]-up (R=220 ohm 3W - 1N4007)
[Link] probe 1 left exhaust
[Link] probe 2 right exhaust
[Link] stand switch
[Link] loads relay
[Link] reserve sensor
[Link] pump
[Link] cylinder injector 1
[Link] cylinder injector 2
[Link] cylinder coil 2
[Link] cylinder coil 1
[Link] in neutral sensor
[Link] pressure sensor

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[Link]-up
[Link] head temperature sensor
[Link] sensor
[Link] G4 control unit
[Link] (if fitted)
[Link] air system
[Link] connector
[Link] left turn indicator (LED)
[Link]
[Link]/low beam bulb
[Link] daylight running light bulb
56.-
[Link] right turn indicator (LED)
[Link] handgrips switch (if fitted)
59.-
[Link] handgrips (where provided)
[Link] handgrips kit provision
[Link]

(LED)

(STONE)

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Key:

1. Multiple connectors
2. air temperature sensor
3. -
4. Instrument cluster
5. -
6. Starter motor relay

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7. Clutch switch
8. Right light switch
9. Front stop switch
[Link]
[Link] light switch
[Link] socket (where applicable)
[Link] light switch
[Link] switch
[Link] right turn indicator (LED)
[Link] (LED)
[Link] plate light (LED)
[Link] left turn indicator (LED)
[Link] (R=220 ohm 3W)
[Link] with the bridge
[Link]-theft (if fitted)
[Link]-theft led (if fitted)
[Link] control unit
[Link] ABS sensor
[Link] ABS sensor
[Link] fuse
[Link]
[Link]
[Link]
[Link]
[Link] motor
[Link]-up (R=220 ohm 3W - 1N4007)
[Link] probe 1 left exhaust
[Link] probe 2 right exhaust
[Link] stand switch
[Link] loads relay
[Link] reserve sensor
[Link] pump
[Link] cylinder injector 1
[Link] cylinder injector 2
[Link] cylinder coil 2
[Link] cylinder coil 1
[Link] in neutral sensor
[Link] pressure sensor

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[Link]-up
[Link] head temperature sensor
[Link] sensor
[Link] G4 control unit
[Link] (if fitted)
[Link] air system
[Link] connector
[Link] left turn indicator (LED)
[Link]
[Link] beam light LED
[Link] beam light LED
[Link]/DRL LED
[Link] right turn indicator (LED)
[Link] handgrips switch (if fitted)
59.-
[Link]/heated handgrips kit provision
[Link]

Cable colour:
Ar orange
Az light 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

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Maintenance icon reset

The system displays the function as follows:

• After the maintenance interval thresh-

olds are exceeded (excepting the first),
an icon with the adjustable wrench is
shown on the digital display.

To reset Service proceed as follows:

• Connect the diagnostic tool;

• Select the concerned model;
• Enter in the "INSTRUMENT PANEL"
section;
• Select "SELF-DIAGNOSIS";
• Select "ACTIVATIONS";
• Enable the command "SERVICE RE-
SET".

Battery recharge circuit

RECHARGING SYSTEM

• Slightly lift the fuel tank, being careful

not to pull the pipes with the relative
hooks;
• Remove the connectors from the com-
partment behind the steering column
• Disconnect the three-way connector
(1) (white).
NOTE
THE ENGINE SIDE IS IDENTIFIED WITH THE LETTER "A"

Measurement of resistance (with engine off)

• For a correct detection of the alternator

resistance, must be performed an am-
bient temperature measurement and
then a further heat stabilisation with a
tester.

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• Take the measurement; The correct value is determined by subtracting the wire resistance
of the tester obtained by touching the two pins.

Example:

• Resistance of stage 1 read on the display = 0.67 Ohm

• Resistance of the wires read on the display = 0.47 Ohm

• Effective resistance stage 1 = 0.67-0.47 = 0.20 Ohm

RESISTANCE MEASURE
Winding stage Ambient temperature (ohm) Afterwards heat stabilisation (ohm)
Stage 1 0.18 - 0.23 0.20 - 0.25

Zero load voltage

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Electrical system V7 E5 Special-Stone

• Disconnect the three-way connector (1);

• For a correct detection of the alternator voltage, a measurement must be carried out using
alternatively the 3 engine side connector pins: stage "1" (pin 1-2), stage "2" (pin 1-3), stage
"3" (pin 2-3)
• Take the measurements;
• If there is a significant difference between one stage and another (other than 15 V), this
means that the alternator is defective and must be replaced.
CAUTION
WITH THE ENGINE HOT THE VALUES RECORDED ARE ON AVERAGE 4-5 V LESS THAN THOSE
DETECTED WITH THE ENGINE COLD.

TENSIONE A VUOTO
Giri / min 2000 4000 6000
Vm tensione concatenata Valori di riferimento ( V 40 - 45 82 - 87 132 - 138
rms )

Short-circuit current

• For a correct detection of the short-cir-

cuit current, a connector must be pre-
pared that generates a downstream
short circuit between the three alterna-
tor cables;
• Start the engine and with a clamp am-
meter measure each single cable.
• If there is a significant difference be-
tween the measure of the single cables
(other than 10 A), this means that the
alternator is defective and must be re-
placed.
CAUTION
WITH THE ENGINE HOT THE VALUES RECORDED ARE
ON AVERAGE 2-3 A LESS THAN THOSE DETECTED WITH
THE ENGINE COLD.
WARNING
NEVER KEEP THE ENGINE RUNNING FOR MORE THAN
ONE MINUTE; FAILURE TO DO SO COULD CAUSE SERI-
OUS OVERHEATING DAMAGES TO THE MOTORCYCLE
CIRCUITS.

COLD SHORT-CIRCUIT CURRENT

RPM 2000 4000 6000 8,000
RMS DC current (Arms) (average of the 3 stage 18 20.4 20.6 20.7
currents)

Voltage on battery poles with engine speed always between 3000 - 5000 RPM

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• Start the engine, after about one minute of operating bring the speed to 3000-5000 RPM,
then measure with a tester the voltage at the battery poles that must always be between
13V and 15V. Otherwise, if the correct operation of the alternator has already been checked,
replace the regulator.
CAUTION
PERFORM THE CHECK DESCRIBED ABOVE WITH A BATTERY IN GOOD CONDITION (START
VOLTAGE ABOUT 13V) MAKING SURE THAT THERE ARE NO ELEMENTS IN THE SHORT CIR-
CUIT.

Start-up system check

pick-up input about 100 A

START-UP
Function
Communicates the motor start request to the con-
trol unit
Operation / Operating principle
By pressing the start button, the related circuit
closes and brings PIN 5 of the control unit to a
voltage equal to zero (ground closure). The starter
button, the clutch switch, the No. 6 starter motor
relay and the injection control unit between PIN 6
and 10 are involved
Level in electrical circuit diagram
Start up
Start-up enabling switches
Position
Under the fuel tank, right side
Electrical specifications

• key released: open circuit

• key pressed: the circuit is closed

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Starter relay pin out

1. control unit relay output (blue/yellow)

2. Control unit ignition switched live (red/green)
3. Starter motor (violet)
4. /
5. Control unit ignition switched live (red/green)

Diagnostic tool - Parameters and statuses

• Starting request - (Absent, Present,

Closed Loop, Closed)
• Start enable - (NO, YES)

Diagnostics tool - Logic errors

Starter button P0512 - signal not valid
Error cause

• Fault in the switch (lock) of the engine start-up or short circuit to ground

Troubleshooting

• Check if the button remains in start position; if not OK, restore, if OK check that there is no
short circuit to ground of the grey/red cable; if it is not, restore. If it is OK, replace

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 (SPECIAL)
Specification Desc./Quantity
Low/high beam light (halogen) 12 V - 55 W / 60 W H4
Front DRL 12 V - 5 W
taillight /stop lights LED
Turn indicators LED
Dashboard lighting LED

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BULBS (STONE)
Specification Desc./Quantity
High beam/low beam light LED
Front DRL LED
taillight /stop lights LED
Turn indicators LED
Dashboard lighting LED

Fuses

(HALOGEN)
FUSE DISTRIBUTION

1. Main fuse, coil 1 and 2, fuel pump, injectors

1 and 2, lambda 1 and 2. (30 A).
2. (Battery positive) MIU G4 ECU, (battery pos-
itive) OBD2. (5 A).
3. (Battery positive) instrument cluster, turn in-
dicators, anti-theft. (5 A).
4. ECU, instrument cluster, anti-fall sensor,
start-up relay, injection load/ABS relay,
clutch, start, anti-theft, canister. (15 A).
5. USB provision, bluedash provision, OBD2
provision, heated handles (if present). (7.5
A).
6. Low beam/high beam lights, passing, DRL/
position lights, stop, horn. (10 A).

(LED)
FUSE DISTRIBUTION

1. Main fuse, coil 1 and 2, fuel pump, injectors

1 and 2, lambda 1 and 2. (30 A).
2. (Battery positive) MIU G4 ECU, (battery pos-
itive) OBD2. (5 A).
3. Instrument cluster permanent position, turn
indicators, anti-theft. (5 A).
4. ECU, instrument cluster, anti-fall sensor,
start-up relay, injection load/ABS relay,
clutch, start, anti-theft, canister. (15 A).
5. USB provision, bluedash provision, OBD2
provision, heated handles (if present). (7.5
A).

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Electrical system V7 E5 Special-Stone

6. Low beam/high beam lights, passing, DRL/

position lights, stop, horn. (10 A).

ABS FUSE LAYOUT

1. ABS ECU (20 A).

2. Spare fuse (20 A).

Battery

Function
Provide electrical supply, the battery is YUASA.
Level in electrical circuit diagram
Battery charge
Position

• on the vehicle: right side, under fairing

• connector: on the battery

Electrical specifications

• 12 V / 12 Ah

Pin-out:

1. Positive pole (red): approx. 12.6 V

2. negative pole (black): ground lead

Diagnostic tool - Parameters and statuses

• Battery voltage - (V) - (Example value

with key ON: 12.0 V, example value
with engine on: 14.2 V)
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING,
CAREFULLY READ THE GENERAL TROUBLESHOOTING
CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN-
NING OF THE CHECK AND CONTROL SECTION IN THE
ELECTRICAL SYSTEM CHAPTER.

Diagnostics tool - Logic errors

Battery voltage P0560 - too high/too low
Error cause

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• If too high: too high a voltage has been detected at PIN 9. If too low: too low a voltage has
been detected at PIN 9. The instrument panel does not indicate the presence of this error
even in the ATT status.

Troubleshooting

• If too high: verify correct operation of the alternator or voltage regulator.

• If too low: carry out the verification procedure for the alternator connector, the engine - ve-
hicle cabling harness connector and the ECU connector (paying particular attention to any
oxidation); if not OK, restore. If OK, check that cable resistance between the alternator cable
and the control unit is a few tenths of Ohm; if not OK, restore wiring harness; if OK, check
correct operation of the electrical alternator; if it is not, replace it. If it is OK, replace the
battery.

Speed sensor

FRONT SPEED SENSOR

Function
To indicate the vehicle speed by reading the front
wheel turning speed
Operation / Operating principle
Magneto-resistive sensor: a square-wave pulse is
generated with voltage approx. between 11.55 V
and 11.25 V
Level in electrical circuit diagram
ABS system
Position

• On the fork, left stanchion, near the

brake calliper mounting bracket

Pin-out

1. Ground (White)
2. Power supply voltage/Output signal (white/
brown)

Diagnostic tool - Parameters and statuses

• Vehicle speed - (km/h)

• Front wheel speed - (km/h)

Diagnostic tool - Electrical errors

Electric malfunction 5D90
Error cause

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Electrical system V7 E5 Special-Stone

• Electrically defective wiring or sensor

Troubleshooting

• Check the sensor connector and the ABS control unit connector. If they are not OK, restore
the connectors. If they are OK, check continuity of the white/brown cable between PIN 2 of
the sensor on the wiring harness side and PIN 14 of the ABS control unit connector If there
is no continuity, restore them. If there is, PIN 2 of the sensor on the wiring harness side, with
the sensor disconnected and key set to ON, must have 12V voltage approximately; if there
is no voltage, check PIN 2 for continuity with the vehicle ground connection: if not ok to
ground, restore the wiring harness. If OK, replace the control unit. If PIN 2 has approx. 12
V, check the continuity of the white cable between PIN 1 of the sensor on the wiring harness
side and PIN 13 of the ABS control unit connector. If there is no continuity, restore the wiring
harness. If there is, replace the logic errors sensor.

Front wheel speed signal/sensor P0501 - signal not valid

Troubleshooting

• Connect to the ABS control unit diagnostics

Diagnostics tool - Logic errors

The signal changes irregularly 5D91
Error cause

• Faulty sensor or signal interference

Troubleshooting

• Check speed sensor retainer; if not ok restore, if ok, check if the tone wheel is dirty, deformed
or wrongly fixed; if it is not OK, replace the tone wheel; if it is OK, replace the speed sensor.

The signal decreases periodically 5D92

Error cause

• Possible tone wheel fault due to deformations or dirt; the surface of the wheel bearings may
be deteriorated. In very rare cases, abnormal tone wheel vibrations

Troubleshooting

• Check if the tone wheel is dirty, deformed or wrongly fixed If the tone wheel is not OK, replace
it. If it is OK, check for possible faults in the wheel bearings; if it is not OK, replace the
bearings.

Missing signal or speed measured too low in relation to the rear wheel 5D93
Error cause

• Faulty sensor or missing sensor/tone wheel. Or excessive distance between the sensor and
the tone wheel or tone wheel with wrong number of teeth

Troubleshooting

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• Check that the speed sensor and the tone wheel are installed; If they are not, install them.
If they are, check the speed sensor retainer; If it is not OK, restore it. If it is, check if the tone
wheel has the correct number of teeth or if it is dirty, deformed or wrongly fixed; if it is not
OK, replace the tone wheel; if it is OK, replace the speed sensor

missing acceleration after pressure reduction 5D94

Error cause

• Faulty sensor or missing sensor/tone wheel or excessive distance between the sensor and
the tone wheel

Troubleshooting

• Check that the speed sensor and the tone wheel are installed; If they are not, install them.
If they are, check the speed sensor retainer; If it is not OK, restore it. If it is, check if the tone
wheel has the correct number of teeth or if it is dirty, deformed or wrongly fixed; if it is not
OK, replace the tone wheel; if it is OK, replace the speed sensor.

Excessive speed detected 5D95

Error cause

• Faulty sensor or tone wheel, or tone wheel with wrong number of teeth or wrong tyre size

Troubleshooting

• Check that the speed sensor and the tone wheel are installed; If they are not, install them.
If they are, check the speed sensor retainer; If it is not OK, restore it. If it is, check if the tone
wheel has the correct number of teeth or if it is dirty, deformed or wrongly fixed; If it is not
OK, replace the tone wheel and if it is OK, check that the tyre size is the correct one If it is
not OK, replace it. If it is OK, check that the tyre pressure is the correct one; if it is not, replace
it. If it is OK, replace the speed sensor

REAR SPEED SENSOR

Function
To indicate the vehicle speed by reading the rear
wheel turning speed
Operation / Operating principle
Magneto-resistive sensor: a square-wave pulse is
generated with voltage approx. between 11.55 V
and 11.25 V
Level in electrical circuit diagram
ABS system
Position

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Electrical system V7 E5 Special-Stone

• On the swingarm, left side, on the rear

brake calliper support plate

Pin-out

1. Earth (Yellow)
2. Power supply voltage/Output signal (yellow/
brown)

Diagnostic tool - Parameters and statuses

• Vehicle speed - (km/h)

• Rear wheel speed - (km/h)

Diagnostic tool - Electrical errors

Electrical malfunction 5DA0
Error cause

• Electrically defective wiring or sensor

Troubleshooting

• Check the sensor connector and the ABS control unit connector; If it is not OK, restore the
connectors; if it is OK, check continuity of the yellow/brown cable between sensor PIN 2 on
the wiring harness side and PIN 11 ABS control unit connector; If there is no continuity,
restore them. If there is, PIN 2 of the sensor on the wiring harness side, with the sensor
disconnected and key set to ON, must have 12V voltage approximately; if there is no voltage,
check PIN 2 for continuity with the vehicle ground connection if not ok to ground, restore the
wiring harness. If OK, replace the control unit. If PIN 2 has approx. 12 V, check continuity
of the yellow cable between PIN 1 of the sensor on the wiring harness side and PIN 12 of
the ABS control unit connector if not OK, restore the wiring harness; if OK, replace the sensor

Rear wheel speed signal/sensor P2158 - signal not valid

Troubleshooting

• Connect to the ABS control unit diagnostics

Diagnostics tool - Logic errors

The signal works irregularly 5DA1
Error cause

• Faulty sensor or signal interference

Troubleshooting

• Check speed sensor retainer; if not ok restore, if ok, check if the tone wheel is dirty, deformed
or wrongly fixed; if it is not OK, replace the tone wheel; if it is OK, replace the speed sensor

The signal decreases periodically 5DA2

Error cause

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• Possible tone wheel fault due to deformations or dirt; the surface of the wheel bearings may
be deteriorated. In very rare cases, abnormal tone wheel vibrations

Troubleshooting

• Check if the tone wheel is dirty, deformed or wrongly fixed If the tone wheel is not OK, replace
it. If it is OK, check for possible faults in the wheel bearings; if it is not OK, replace the
bearings

No signal or speed measured too low in relation to the front wheel 5DA3
Error cause

• Faulty sensor or missing sensor/tone wheel. Or excessive distance between the sensor and
the tone wheel or tone wheel with wrong number of teeth

Troubleshooting

• Check that the speed sensor and the tone wheel are installed; If they are not, install them.
If they are, check the speed sensor retainer; If it is not OK, restore it. If it is, check if the tone
wheel has the correct number of teeth or if it is dirty, deformed or wrongly fixed; if it is not
OK, replace the tone wheel; if it is OK, replace the speed sensor

Missing acceleration after pressure reduction 5DA4

Error cause

• Faulty sensor or missing sensor/tone wheel or excessive distance between the sensor and
the tone wheel

Troubleshooting

• Check that the speed sensor and the tone wheel are installed; If they are not, install them.
If they are, check the speed sensor retainer; If it is not OK, restore it. If it is, check if the tone
wheel has the correct number of teeth or if it is dirty, deformed or wrongly fixed; if it is not
OK, replace the tone wheel; if it is OK, replace the speed sensor

Excessive speed detected 5DA5

Error cause

• Faulty sensor or tone wheel, or tone wheel with wrong number of teeth or wrong tyre size

Troubleshooting

• Check that the speed sensor and the tone wheel are installed; If they are not, install them.
If they are, check the speed sensor retainer; If it is not OK, restore it. If it is, check if the tone
wheel has the correct number of teeth or if it is dirty, deformed or wrongly fixed; If it is not
OK, replace the tone wheel and if it is OK, check that the tyre size is the correct one If it is
not OK, replace it. If it is OK, check that the tyre pressure is the correct one; if it is not, replace
it. If it is OK, replace the speed sensor

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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
Position

• Sensor: engine front left section, under

the left cylinder
• Connector: under the fuel tank

Electrical specifications

• Winding resistance: 650 Ω ± 15% Out-

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

Pin-out

1. Engine revolution sensor positive signal (X2)

2. Engine revolution sensor negative signal
(X1)
3. Engine speed sensor anti-jamming cable
(blue/green)

Diagnostic tool - Parameters and statuses

• Engine speed - (rpm)

• Target engine revs - (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)

Diagnostic tool - Electrical errors

Engine revolution sensor P0335 - open circuit
Error cause

• Faulty wiring harness or engine revolution sensor (pick up)

Troubleshooting

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• An interruption in the sensor circuit has been detected, from PIN 20 to PIN 29 of the control
unit connector.
• Check the sensor connector and the injection ECU connector: If the values are incorrect
restore them.
• If the values are correct, check the continuity of the two cables that go from PIN 20 to PIN
29 of the control unit connector; if not OK, restore the wiring harness; if OK, check the
continuity of the sensor; replace it if not OK.

Installation
The gap width should be between 0.7 and 0.9 mm.
Engine revolution sensor P0336 - inconsistent signal
Error cause

• Possible false contact in the electric circuit detected at PIN 20 and 29 of the engine control
unit connector

Troubleshooting

• Check the electric circuit is in good conditions and the flywheel teeth cleaning and correct
positioning of the sensor in its own housing; if it is not, replace it. If it is OK, replace the
sensor

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
Position

• On the right head, towards the inside

of the "V" of the engine
• Connector: on the sensor

Electrical specifications

• 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%

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Electrical system V7 E5 Special-Stone

• Resistance at 80°C: 0.377 kΩ ± 5%

• Resistance at 100°C: 0.204 kΩ ± 5%

Pin-out

• 0-5 V signal (grey wiring harness side)

• Ground (blue/green wiring harness
side)

Diagnostic tool - Parameters and statuses

• Engine temperature - (°C)

Diagnostic tool - Electrical errors

Engine temperature sensor P0115 - shorted to positive or open circuit / shorted to negative.
Error cause

• Short-circuit to positive or open circuit: interruption of the circuit or excessive voltage at PIN
13 of the control unit connector
• Short-circuit to negative: zero voltage between PIN 13 and 15 of the control unit connector

Troubleshooting
Short-circuit to positive:

• With the sensor connector and the control unit disconnected, verify that the fault is shorted
with the battery positive of sensor connector PIN 2 (or control unit PIN 13) and restore the
wiring harness.

Open circuit:

• Disconnect the connector of the control unit.

• Measure the resistance value of the sensor at different temperatures between PIN 13 and
15.
• Disconnect the sensor connector.
• Verify continuity of the wiring harness between the sensor connector and the control unit
connector: Control unit PIN 13 - sensor PIN 2 and control unit PIN 15 - sensor PIN 1. If
necessary, restore the wiring harness.
• If the wiring harness is intact but the sensor resistance value is incorrect, this means that
the sensor is faulty and must be replaced, otherwise proceed with the checks.

Short-circuit to negative:

• Disconnect the sensor connector.

• Check the sensor connector PIN 2 ground insulation.
• If there is no ground insulation restore the wiring harness.

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• If PIN 2 is insulated from the ground and the error persists, this means that there is a probable
fault in the control unit.

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
RIGHT LAMBDA
Level in electrical circuit diagram
Lambda probe
Position

• Sensor: right exhaust pipe

• Connector: near the throttle body right
side

Electrical specifications

• Heater circuit: 12 -14 Ω at 20 °C (68 °

F)

Pin-out

1. Positive signal sensor (grey/white)

2. Negative signal sensor (green/white)
3. Heater ground (white/yellow)
4. Heater power (red/brown cable)

Diagnostic tool - Parameters and statuses

• Oxygen sensor voltage RH - (mV)

• Right lambda probe - (---, Not enabled,
Not active (start), Not active (heat.),
Not active (rich), Operating, Not active
(lean), Fault

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Diagnostic tool - Activation

• Lambda probe heater 2

Diagnostic tool - Electrical errors
Control of the air-fuel ratio / Right lambda probe P0150 - positive short circuit / open circuit, short
circuit to negative / signal not valid.
Error cause
• Short-circuit to positive: excessive voltage at PIN 18 or PIN 12 of the control unit connector.
• Open circuit or short-circuit to negative: interruption of the circuit or null voltage between
control unit connector PIN 18 and 12
Troubleshooting
Short-circuit to positive:
• Disconnect the control unit connector and the sensor connector.
• Verify that there is no short to battery positive on sensor connector PIN 1 (corresponding to
control unit connector PIN 18); if there is a short, restore the wiring harness.
• Verify that there is no short to battery positive on sensor connector PIN 2 (corresponding to
control unit connector PIN 12); if there is a short, restore the wiring harness.
Open circuit:
• Disconnect the control unit connector and the sensor connector.
• Verify continuity of the wiring harness between the sensor connector and the control unit
connector: Control unit PIN 18 - sensor PIN 1 and control unit PIN 12 - sensor PIN 2. If
necessary, restore the wiring harness.
• If the wiring harness is intact and the error persists, proceed with the following checks.
Short-circuit to negative:
• Disconnect the sensor connector and the control unit connector.
• Check the sensor connector PIN 1 ground insulation. In the absence of insulation restore
the wiring harness.
• Check the sensor connector PIN 2 ground insulation. In the absence of insulation restore
the wiring harness.
• If PIN 1 and PIN 2 are insulated from the ground and the error persists, this means that there
is a probable fault in the control unit.
Lambda probe heater P0155 - short circuit to positive / open circuit / short circuit to negative.
Error cause
• Short-circuit to positive: excessive voltage at PIN 2 of the control unit connector.
• Short-circuit to negative: lack of insulation from ground on the sensor connector PIN 4
• Open circuit: circuit interruption.
Troubleshooting
Short-circuit to positive:

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• Disconnect the control unit connector and the sensor connector.

• Verify that there is no short to battery positive on sensor connector PIN 3 (corresponding to
control unit connector PIN 2); if there is a short, restore the wiring harness.

Open circuit:

• Disconnect the control unit connector and the sensor connector.

• Verify continuity of the wiring harness between the sensor connector and the control unit
connector: Control unit PIN 2 - sensor PIN 3. If necessary, restore the wiring harness.
• Verify continuity of the wiring harness between the sensor connector and the injection relay:
sensor PIN 4 - injection relay PIN 3. If necessary, restore the wiring harness.
• If the wiring harness is intact and the error persists, proceed with the following checks.

Short-circuit to negative:

• Disconnect the sensor connector.

• Check the sensor connector PIN 3 ground insulation. In the absence of insulation restore
the wiring harness.
• If PIN 3 is insulated from ground and in the absence of other errors (fuel pump, injector, coil),
this means that the control unit is most likely faulty.

LEFT LAMBDA
Level in electrical circuit diagram
Lambda probe
Position

• Sensor: left exhaust pipe

• Connector: adjacent to the filter box,
left side

Electrical specifications:

• Heater circuit: 12 -14 Ω at 20 °C (68 °

F)

Pin-out

1. Positive sensor signal (pink)

2. Negative signal sensor (green/white)
3. Heater ground (violet/white)
4. Heater power (red/brown cable)

Diagnostic tool - Parameters and statuses

• Oxygen sensor voltage LH - (mV)

• Left lambda probe - (---, Not enabled,
Not active (start), Not active (heat.),

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Not active (rich), Operating, Not active

(lean), Fault

Diagnostic tool - Activation

• Lambda probe heater 1

Diagnostic tool - Electrical errors

Control of the air-fuel ratio / Left lambda probe P0130 - positive short circuit / open circuit, short
circuit to negative / signal not valid.
Error cause

• Short-circuit to positive: excessive voltage to PIN 11 or PIN 12 of the control unit connector
• Open circuit or short-circuit to negative: interruption of the circuit or null voltage between
control unit connector PIN 11 and 12

Troubleshooting
Short-circuit to positive:

• Disconnect the control unit connector and the sensor connector.

• Verify that there is no short to battery positive on sensor connector PIN 1 (corresponding to
control unit connector PIN 11); if there is a short, restore the wiring harness.
• Verify that there is no short to battery positive on sensor connector PIN 2 (corresponding to
control unit connector PIN 12); if there is a short, restore the wiring harness.

Open circuit:

• Disconnect the control unit connector and the sensor connector.

• Verify continuity of the wiring harness between the sensor connector and the control unit
connector: Control unit PIN 11 - sensor PIN 1 and control unit PIN 12 - sensor PIN 2. If
necessary, restore the wiring harness.
• If the wiring harness is intact and the error persists, proceed with the following checks.

Short-circuit to negative:

• Disconnect the sensor connector and the control unit connector.

• Check the sensor connector PIN 1 ground insulation. In the absence of insulation restore
the wiring harness.
• Check the sensor connector PIN 2 ground insulation. In the absence of insulation restore
the wiring harness.
• If PIN 1 and PIN 2 are insulated from the ground and the error persists, this means that there
is a probable fault in the control unit.

Lambda probe heater P0135 - shorted to positive / shorted to negative / open circuit.
Error cause

• Short-circuit to positive: excessive voltage at PIN 31 of the control unit connector

• Short-circuit to negative: lack of insulation from ground on the sensor connector PIN 4

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• Open circuit: circuit interruption.

Troubleshooting
Short-circuit to positive:

• Disconnect the control unit connector and the sensor connector.

• Verify that there is no short to battery positive on sensor connector PIN 3 (corresponding to
control unit connector PIN 31); if there is a short, restore the wiring harness.

Short-circuit to negative:

• Disconnect the sensor connector.

• Check the sensor connector PIN 3 ground insulation. In the absence of insulation restore
the wiring harness.
• If PIN 3 is insulated from ground and in the absence of other errors (fuel pump, injector, coil),
this means that the control unit is most likely faulty.

Open circuit:

• Disconnect the control unit connector and the sensor connector.

• Verify continuity of the wiring harness between the sensor connector and the control unit
connector: Control unit PIN 31 - sensor PIN 3. If necessary, restore the wiring harness.
• Verify continuity of the wiring harness between the sensor connector and the injection relay:
sensor PIN 4 - injection relay PIN 3. If necessary, restore the wiring harness.
• If the wiring harness is intact and the error persists, proceed with the following checks.

Injector

Function
To supply the correct amount of petrol at the right
timing
Operation / Operating principle
Injector coil is energised for the petrol passage to
open
RIGHT INJECTOR
Level in electrical circuit diagram
Coils and injectors
Right injector position

• On the intake manifold

• Connector: on injector

Electrical specifications

• 14.8 Ohm +/- 5% (at 20 °C - 68 °F)

Pin-out

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1. Power 12V (red/brown)

2. Ground (grey/red)

Diagnostic tool - Parameters and statuses

• Injection time cyl. RH - (ms)

Diagnostic tool - Activation

• Right injector
• Injector control

Diagnostic tool - Electrical errors

Front injector P0202 - shorted to positive / shorted to negative / open circuit.
Error cause

• Short-circuit to positive: excessive voltage at PIN 32 of the control unit connector

• Short-circuit to negative: zero voltage at PIN 1 of the right injector connector
• Open circuit: circuit interruption

Troubleshooting
Short-circuit to positive:

• Disconnect the right injector connector, turn the key to ON and activate the component
through the diagnostic tool.
• Verify the absence of voltage at the right injector connector PIN 2; if present restore the
wiring harness, otherwise proceed with the following checks.

Short-circuit to negative:

• Disconnect the right injector connector, turn the key to ON and activate the component
through the diagnostic tool.
• Verify the presence of voltage at the ends of the right injector connector; if there is no voltage,
restore the wiring harness, otherwise proceed with the following checks.

Open circuit:

• Carry out the check procedure of the right injector and control unit connectors.
• Verify continuity of the wiring harness between the control unit connector and the right in-
jector connector (control unit PIN 32 - right injector PIN 2). In the absence of continuity
restore the wiring harness.

LEFT INJECTOR
Level in electrical circuit diagram:
Coils and injectors
Left injector position:

• On the intake manifold

• Connector: on injector

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Electrical specifications

• 14.8 Ohm +/- 5% (at 20 °C - 68 °F)

Pin-out:

1. Power 12V (red/brown)

2. Ground (grey/black)

Diagnostic tool - Parameters and statuses

• Injection time cyl. LH - (ms)

Diagnostic tool - Activation

• Left injector
• Injector control

Diagnostic tool - Electrical errors

Left injector P0201 - shorted to positive / shorted to negative / open circuit.
Error cause

• Short-circuit to positive: excessive voltage at PIN 34 of the control unit connector

• Short-circuit to negative: zero voltage at PIN 1 of the left injector connector
• Open circuit: circuit interruption

Troubleshooting
Short-circuit to positive:

• Disconnect the left injector connector, turn the key to ON and activate the component
through the diagnostic tool.
• Verify the absence of voltage at the left injector connector PIN 2; if present restore the wiring
harness, otherwise proceed with the following checks.

Short-circuit to negative:

• Disconnect the left injector connector, turn the key to ON and activate the component
through the diagnostic tool.
• Verify the presence of voltage at the ends of the left injector connector; if there is no voltage,
restore the wiring harness, otherwise proceed with the following checks.

Open circuit:

• Carry out the check procedure of the left injector and control unit connectors.
• Verify continuity of the wiring harness between the control unit connector and the left injector
connector (control unit PIN 34 - left injector PIN 2). In the absence of continuity restore the
wiring harness.

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Fuel pump
Function
Fuel pump: keeps pressure of the injectors supply
duct.
Low fuel: tells to the instrument panel about low
fuel
Operation / Operating principle
The fuel reserve is a resistance that if correctly
supplied varies its electrical resistance if it is dam-
ped or not by petrol
Level in electrical circuit diagram
Injection load solenoid
Low fuel and oil pressure
Position

• On the vehicle: on the tank.

• Connector: on the front left part of the
bike, under the fuel tank.

Fuel pump pin-out and fuel reserve sensor

1. Power 12V (red/brown)

2. Ground (black)
3. Positive signal to instrument panel (orange/
violet)
4. Ground (brown)
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING,
CAREFULLY READ THE GENERAL TROUBLESHOOTING
CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN-
NING OF THE CHECK AND CONTROL SECTION IN THE
ELECTRICAL SYSTEM CHAPTER.

Diagnostic tool - Activation

• Fuel pump
Diagnostic tool - Electrical errors
Fuel pump relay control P0230 - shorted to positive / shorted to negative / open circuit.
Error cause
Short-circuit to positive:
• Excessive voltage to PIN 22 of the control unit connector.
Short-circuit to negative:
• null voltage at PIN 2 of the injection loads relay.
Open circuit:

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• Circuit interruption.

Troubleshooting
Short-circuit to positive:

• Disconnect the injection loads relay (No. 28 on the electrical circuit diagram), turn the key
to the ON position and activate the injection loads relay through the diagnostic tool.
• Verify the presence of voltage between injection loads relay connector PIN 1 and 2 toward
the wiring harness.
• If no voltage is read, disconnect the control unit and verify insulation from battery positive
of the injection loads relay PIN 1 (or control unit PIN 22). If necessary, restore the wiring
harness.

Short-circuit to negative:

• Disconnect the injection loads relay (No. 28 on the electrical circuit diagram) and the control
unit.
• Verify ground insulation of the injection loads relay connector PIN 1 and 2 toward the wiring
harness: if there is no insulation, restore the wiring harness.

Open circuit:

• Disconnect the injection loads relay (No. 28 on the electrical circuit diagram) and the control
unit.
• Verify continuity of the wiring harness between the injection loads relay and control unit:
Injection loads relay PIN 1 - control unit PIN 22. If necessary, restore the wiring harness.

Coil

Function
It controls the ignition spark plug in order to gen-
erate the fuel ignition spark.
Operation / Operating principle
Inductive discharge system.
LEFT COIL
Level in electrical circuit diagram
Coils and injectors
Position

• Centred under the fuel tank.

• Connector: on the coil.

Electrical specifications

• Primary winding resistance: 550 kΩ ±

10%

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• Secondary winding resistance: 3 kΩ ±

10%
• Tube resistance 5 kΏ

Pin-out

1. Circuit ground (orange/white)

2. Power supply (red/brown)

Diagnostic tool - Activation

• Left coil
• Coil command

Diagnostic tool - Electrical errors

H.V. Coil P0351 - shorted to positive / open circuit or short-circuit to negative.
Error cause

• Short-circuit to positive: excessive voltage at PIN 1 of the control unit connector

• Open circuit or short-circuit to negative: interruption of the circuit or zero voltage at PIN 1 of
the control unit connector

Troubleshooting
Short-circuit to positive:

• Disconnect the left coil connector, turn the key to ON and activate the component through
the diagnostic tool.
• Verify the presence of voltage on the left coil connector PIN 1: if present, restore the wiring
harness, otherwise replace the left coil.

Open circuit:

• Carry out the check procedure of the left coil and control unit connectors.
• Verify continuity of the wiring harness between the left coil and control unit: Left coil PIN 1
- control unit PIN 1. In the absence of continuity restore the wiring harness.
• Verify, with the key turned ON, the presence of voltage on the left coil connector PIN 2. If
no voltage is read, verify the continuity of the wiring harness between left coil and injection
loads relay (No. 28 on the electrical circuit diagram): Left coil PIN 2 - injection loads relay
PIN 3.
• If the above tests provided a positive result, the left coil should be replaced.

Short-circuit to negative:

• Disconnect the control unit connector and the left coil connector.
• Verify the left coil connector PIN 1 ground insulation (or control unit connector PIN 1). If
necessary, restore the wiring harness.

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RIGHT COIL
Level in electrical circuit diagram
Coil 2 (right cylinder)
Position

• Centred under the fuel tank.

• Connector: on the coil.

Electrical specifications

• Primary winding resistance: 550 kΩ ±

10%
• Secondary winding resistance: 3 kΩ ±
10%
• Tube resistance 5 kΏ

Pin-out

1. Power supply (red/brown)

2. Power ground 2 (blue)
3. Circuit ground (orange/red)

Diagnostic tool - Activation

• Right coil
• Coil command

Diagnostic tool - Electrical errors

H.V. Coil P0352 - shorted to positive / open circuit or short-circuit to negative.
Error cause

• Short-circuit to positive: excessive voltage at PIN 8 of the control unit connector

• Open circuit or short-circuit to negative: interruption of the circuit or zero voltage at PIN 8 of
the control unit connector

Troubleshooting
Short-circuit to positive:

• Disconnect the right coil connector, turn the key to ON and activate the component through
the diagnostic tool.
• Verify the presence of voltage on the right coil connector PIN 3: if present, restore the wiring
harness, otherwise replace the right coil.

Open circuit:

• Carry out the check procedure of the right coil and control unit connectors.
• Verify continuity of the wiring harness between the right coil and control unit: Right coil PIN
3 - control unit PIN 8. In the absence of continuity restore the wiring harness.

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• Verify, with the key turned ON, the presence of voltage on the right coil connector PIN 1. If
no voltage is read, verify the continuity of the wiring harness between right coil and injection
loads relay (No. 28 on the electrical circuit diagram): Right coil PIN 1 - relay PIN 3.
• If the above tests provided a positive result, the right coil should be replaced.

Short-circuit to negative:

• Disconnect the control unit connector and the right coil connector.
• Verify the right coil connector PIN 3 ground insulation (or control unit connector PIN 8). If
necessary, restore the wiring harness.

Neutral sensor

Function
Indicates 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 neu-
tral warning light
Level in electrical circuit diagram
Neutral sensor
Position

• Sensor: rear / upper side of the gear-

box
• Connector: on the sensor

Electrical specifications

• Gear in neutral: closed circuit (0 V on

wire from control unit to sensor / switch
in continuity).
• Gearshift engaged: open circuit (12 V
on the wire from control unit to sensor)

Pin-out:

1. Voltage 12V (green/black)

Diagnostic tool - Parameters and statuses

• Gear in neutral - (YES, NO)

Diagnosis
Warning light "N" always off
Error cause

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• Possible malfunction

Troubleshooting

• Carry out the check procedure on the green/black sensor/control unit cable.
• Restore if damaged.
• If OK, with the transmission in neutral, check for continuity to ground of the sensor connector.
• If there is no continuity, replace the sensor.
• Restore if damaged.
• If OK, check continuity.
• If there is no continuity, restore the wiring harness.
• If OK, replace the instrument panel if the vehicle performs properly.

Warning light "N" always on

Error cause

• Possible malfunction

Troubleshooting

• Disconnect the terminals from the sensor and verify that, with the transmission in gear, there
is continuity with the ground.
• If there is continuity, replace the sensor.
• If there is no continuity this means that there is a short to ground of the green black cable
which goes to PIN 3 of the control unit, therefore restore the wiring harness.
• If there is no continuity, restore the wiring harness.
• If there is no continuity, replace the wiring harness.

Clutch lever sensor

Function
Indicates the clutch lever position to the control
unit
Operation / Operating principle
In order to start the engine, pull the clutch also with
the gear in neutral
Level in electrical circuit diagram
Start enable.
Position

• sensor: under clutch lever

• Connector: under the fuel tank on right
side

Electrical specifications

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• Clutch pulled: closed circuit (continui-

ty)
• Clutch released: open circuit (infinite
resistance)

Pin-out

1. 12 V Voltage (brown/white)
2. Ground (blue/green)

Diagnostic tool - Parameters and statuses

• Clutch - (Pulled, Released)

Diagnosis
Even with the clutch lever pulled, the vehicle does not start
Error cause

• Possible malfunction

Troubleshooting

• Verify that, if a gear is engaged, the stand is up.

• If it is up, check continuity of the brown/white cable and control unit PIN 14.
• If there is no continuity, restore the wiring harness.
• If there is continuity, disconnect the sensor and, with the clutch pulled, check for continuity
between the two sensor PINs.
• If absent, replace the sensor.
• If present, check for continuity of the blue/green cable between the sensor and control unit
PIN 15.
• If absent, restore the wiring harness.

The vehicle starts even without pulling the clutch lever

Error cause

• Possible malfunction

Troubleshooting

• Disconnect the terminals from the sensor and check that, with the clutch released, there is
continuity between the two PINs.
• If there is continuity, replace the sensor.
• If there is no continuity, this means that the blue/green cable which goes from the sensor
PIN 2 to the control unit PIN 15 is shorted to ground.

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Side stand sensor

Function
Indicates the side stand position to the control unit
Operation / Operating principle
If the gear is engaged and the side stand is unfol-
ded, 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 electrical circuit diagram
Start-up enabling switches
Position

• Sensor: on side stand supporting plate

• Connector: left side, near the starter
motor

Electrical specifications

• Side Stand Up: closed circuit (continu-

ity)
• Side Stand Down: open circuit (infinite
resistance)

Pin-out

1. Ground (blue/green)
2. 12 V voltage (grey/yellow)

Diagnostic tool - Parameters and statuses

• Side stand - (Up, Down)

Diagnosis
The vehicle with clutch pulled, gear engaged and side stand retracted does not start (side stand
switch always open)
Error cause
• Possible malfunction

Troubleshooting
• verify continuity of the grey/yellow cable between the sensor and PIN 19 of the control unit.
• If absent, restore the wiring harness, if present, with the stand up, check for continuity be-
tween the two PINs on the sensor. If absent, replace the sensor. If present, check for
continuity to ground of the blue/green cable on the wiring harness side connector.

The vehicle, with clutch operated and gear engaged, starts but with the side stand extended
Error cause

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Electrical system V7 E5 Special-Stone

• Possible malfunction

Troubleshooting

• disconnect the sensor connector and check that, with side stand extended, there is not
continuity between the two PINS.
• If present, replace the sensor. If absent, disconnect from control unit PIN 19 and check
insulation from the ground of the grey/yellow cable between sensor and control unit.

Bank angle sensor

Function
It tells the vehicle position to the control unit
Operation / Operating principle
The sensor operates by sending an engine stop
signal to the control unit, in cases where the vehi-
cle detects an inclination greater than ~ 60 ° (for
example, due to slips or falls)
Level in electrical circuit diagram
Start-up enabling switches
Position

• On the vehicle: under the tank.

• Connector: near the sensor.

Pin-out

1. /
2. Ground (blue/green)
3. Power supply (grey/green)
4. Signal/consent (grey/sky blue)

Diagnostic tool - Parameters and statuses

• Tipping sensor - (Engine inhibited,

Gear allowed, YES, Lean, Rich, Rich
title, Error, Lean title)
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING,
CAREFULLY READ THE GENERAL TROUBLESHOOTING
CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN-
NING OF THE CHECK AND CONTROL SECTION IN THE
ELECTRICAL SYSTEM CHAPTER.

Diagnosis
The engine stop button is in "ON" but its status remains in "OFF"
Error cause

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• Possible malfunction caused by the fall sensor or RUN-STOP switch

Troubleshooting

• See diagnosis "RUN-STOP switch", if not ok check the correct status of the fall sensor

SAS valve actuator

Function
Improves the reaction of oxide, reduction after
combustion
Operation / Operating principle
The valve coil is excited to open the air passage
of the filter box to the exhaust manifold
Level in electrical circuit diagram
Secondary air valve
Position:

• on the vehicle: under the fuel tank, in

the middle of the "V" of the engine, at-
tached to the chassis
• connector: on the valve

Electrical specifications

• Resistance at ambient temperature: 21

+3/- 1 Ω

Pin-out

1. Power supply (red/brown)

2. Ground (black/white)

Diagnostic tool - Parameters

• Example value with key ON: 0 %

• Example value with engine on: %

Used only at 0 or 100%

CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING,
CAREFULLY READ THE GENERAL TROUBLESHOOTING
CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN-
NING OF THE CHECK AND CONTROL SECTION IN THE
ELECTRICAL SYSTEM CHAPTER.

Diagnostic tool - Activation

• EV secondary air system

Diagnostics tool - Logic errors

Error cause

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Electrical system V7 E5 Special-Stone

• Possible malfunction

Troubleshooting

• Disconnect the connector and check the resistance between PIN of the valve connector; if
the resistance value is close to 10-20 Ω the valve is ok, if the value of the resistance is equal
to 0 it can be said that there is a short circuit on the valve, instead if there is a resistance
equal to a ∞ this means that inside the valve occurs an open circuit; in both cases it is
necessary to replace the valve

Secondary air valve P0410 - shorted to positive / shorted to negative / open circuit
Error cause

• Short-circuit to positive: excessive voltage measured at PIN 24 of the engine control unit
• If shorted to negative/open circuit: no voltage has been detected. The instrument panel does
not indicate the presence of this error even in the ATT status.

Troubleshooting

• Short-circuit to positive: disconnect the component, set the key to ON, start the vehicle and
check if the error symptom is still "shorted to positive": it means that short circuit is between
black/white cable and a cable in voltage, therefore restore wiring harness; if the error symp-
tom is short circuit to ground, it means that short circuit is inside the valve and therefore,
you must replace the component.
• If shorted to negative or open circuit: check the component connector and control unit con-
nector: if not OK, restore; if they are OK, check the continuity of the black/white cable
between the two connectors: if not OK, restore wiring harness; if OK, with key ON, check if
there is voltage at PIN 1: if there is not voltage, check red/brown cable; if there is voltage,
check component electrical characteristics and replace the component

RUN/STOP switch

Function
Indicates the control unit if the rider wishes to en-
able engine start-up or to keep the engine running
Operation / Operating principle
If the driver wants to shut off the engine or to dis-
able engine start-up, the switch should be open,
i.e. the Marelli control unit should not detect volt-
age at PIN 4 of the control unit connector
Level in electrical circuit diagram
Start-up enabling switches
Position

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• Sensor: right light switch

• Connector: next to the headstock, right
side

Electrical specifications

• STOP position: open circuit

• RUN position: closed circuit (continui-
ty)

Pin-out

1. Voltage 0 V with engine kill in STOP; 12V if engine kill in RUN (pink/yellow cable)
2. Always voltage 12 V (with key on) (red/yellow cable)

Diagnostic tool - Parameters and statuses

• RUN/OFF Switch - (RUN-OFF)

Diagnosis
Engine does not start
Error cause

• Possible malfunction

Troubleshooting

• Disconnect the connector and check, with the switch set to RUN, that there is continuity
between the two grey/light blue and red/grey cables (sensor side); If not ok, replace the
sensor; if ok, check the connector; if not ok, restore the wiring harness; if ok, check, with key
set to ON, if there is voltage on Yellow/Red cable (wiring harness side). If not ok,restore the
wiring harness; if ok, check the red/yellow cable ground insulation (wiring harness side); If
there is continuity with ground connection, restore the wiring harness; if it is OK, set the key
to KEY OFF and check the engine control unit connector; if it is OK, replace the engine
control unit

Engine does not shut off with switch in "STOP"

Error cause

• Possible malfunction

Troubleshooting

• Disconnect the connector and verify, with the switch set to STOP, that there is continuity
between the two grey/light blue and red/grey cables (sensor side). If present, replace the
switch; if absent this means that, with the key ON, the pink/yellow cable shorts to positive;
if not OK, restore the wiring harness; if OK, replace the engine control unit

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Electrical system V7 E5 Special-Stone

Connectors

ECU

Function
It manages injection/ignition, the system safety
checks and the self-diagnosis function. The con-
trol unit is Magneti Marelli MIU G4
Level in electrical circuit diagram
Secondary air system
Bluedash pre-installation
Antitheft device
ABS system
Diagnosis
Low beam and running lights logic
High-beam lights logic
CAN Line
Temperature sensors
Lambda probe
Neutral sensor
Engine speed sensor
Coils and injectors
Injection loads relay
ECU base power circuit
Starting
Start enable switches
Position

• on the vehicle: under the tank, near the

battery
• connector: on the control unit from 34
PIN

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V7 E5 Special-Stone Electrical system

Pin-out

1. Left coil command output (1)

2. Right Lambda heater command output (2)
3. -
4. Run-off control input
5. Start button inlet
6. Ignition switch positive
7. Ground 1 (-)
8. Right coil command output (2)
9. Battery positive 12V
[Link] motor relay command output
[Link] lambda probe positive signal (1)
[Link] lambda probe negative signal (1)
[Link] sensor input
[Link] switch signal
[Link] sensor ground
[Link] lambda probe negative signal (2)
17.-
[Link] lambda probe positive signal (2)
[Link] stand switch and fall sensor input
[Link] revolution sensor negative signal
(pick up)
[Link] in neutral sensor
[Link] relay command output
[Link] 2 (power)
[Link] air system control
25.-
[Link] H line
[Link] L line
[Link]
[Link] revs positive signal (pick up)
30.-
[Link] Lambda heater command output (1)
[Link] injector command output (2)
[Link] relay command output
[Link] injector command output(1)

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Electrical system V7 E5 Special-Stone

Diagnostic tool - Control unit info screen page

In this screen page are read the general data re-
garding the control unit, for example: type of soft-
ware, mapping, control unit programming data

• ISO code
• Drawing number (identification inser-
ted by manufacturer)
• HW number (hardware number)
• SW ver. (software version)
• Approval number
• Author last progr. (author of the last
programming)
• HW MM version (hardware MM ver-
sion)
• Mapping (indicates the mapping num-
ber)
• Manufacturing data (control unit man-
ufacturing data)
• Programming data (control unit pro-
gramming data)
• NIP code

Diagnostic tool - Parameters and statuses

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); in addition to the
parameters in this screen page, are also shown
the status of the vehicle devices or the operation
condition of some vehicle systems (for example,
lambda probe functioning status)

• Engine speed - (rpm)

• Complete throt. angle - (°)
• Engine temperature - (°C)
• Intake air temperature - (°C)
• Oxygen sensor voltage LH - (mV)
• Oxygen sensor voltage RH - (mV)
• Corr. title cylinder LH - (%)

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V7 E5 Special-Stone Electrical system

• Corr. title cylinder RH - (%)

• Corr. title carb. cyl. LH - (%)
• Corr. title carb. cyl. RH - (%)
• Steps carried out - (step)
• Programmed steps - (step)
• Advance cylinder LH - (°)
• Advance programmed - (°)
• Advance cylinder RH - (°)
• Injection time cyl. LH - (ms)
• Injection time cyl. RH - (ms)
• Atmospheric pressure - (mbar)
• Intake pressure - (mbar)
• Battery voltage - (V)
• Minimum target revs - (rpm)
• Throttle valve equiv. stepper - (°)
• Vehicle speed - (km/h)
• Ctrl title cylinder LH - (Open Loop,
Closed Loop, Not allowed, Ecu univer-
sal code, ---, Recovery, Fault, Key not
OK, Timeout)
• Lean title cyl. LH - (NO, YES)
• Rich title cyl. LH - (NO, YES)
• Right lambda probe - (---, Not enabled,
Not active (start), Not active (heat.),
Not active (rich), Operating, Not active
(lean), Fault
• Left lambda probe - (---, Not enabled,
Not active (start), Not active (heat.),
Not active (rich), Operating, Not active
(lean), Fault
• Ctrl title cylinder RH - (Open Loop,
Closed Loop)
• Lean title cyl. RH - (NO, YES)
• Rich title cyl. RH - (NO, YES)
• Idle motor - (start ready, Open Loop,
Closed Loop, delayed start, acceler-
ated start, Minimum compensated,
Stable out of min., Minimum, Acceler-

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Electrical system V7 E5 Special-Stone

ation, Deceleration, Cut-off, Restore

Cut-off)
• Throttle valve status - (---, Minimum,
Full power, partial position)
• Engine status - (Undetermined, Po-
wON/Engine off, KeyON/engine off,
Rotation, Engine Stall, Pwr latch in pro-
gress, [Link] Term, Stop, Syn-
chronis. 4 strokes)
• Engine mode - (Undetermined, Start,
Stabilised, delayed start, accelerated
start, Minimum compensated, Stable
out of min., Minimum, Acceleration,
Deceleration, Cut-off, Restore Cut-off)
• Synchronised panel - (NO, YES, Parti-
ally, --- , Error)
• 4Stroke cycle - (Not synchronised,
Synchronised)
• Starting request - (Absent, Present,
Closed Loop, Closed)
• Start enable - (NO, YES)
• RUN/OFF Switch - (RUN-OFF)
• Tipping sensor - (Engine inhibited,
Gear allowed, YES, Lean, Rich, Rich
title, Error, Lean title)
• Side stand - (Up, Down)
• Gear in neutral - (YES, NO)
• Clutch - (Pulled, Released)
• Front wheel speed - (km/h)
• Rear wheel speed - (km/h)
• Traction control (MGCT) - (Disabled,
Enabled, Complete, Lean, Rich, Oper-
ating)
• Number of enabled keys - (.)
• Previously unused Ecu - (NO, YES)
• Start enabled - (NO, YES)
• Previously unused Ecu-universal c. -
(NO, YES)

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V7 E5 Special-Stone Electrical system

• Unlock with gas - (NO, YES)

• Key or antenna faulty - (NO, YES)
• Wrong code - (NO, YES)
• Communication timeout - (NO, YES)
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING,
CAREFULLY READ THE GENERAL TROUBLESHOOTING
CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN-
NING OF THE CHECK AND CONTROL SECTION IN THE
ELECTRICAL SYSTEM CHAPTER.

Diagnostic tool - Activation

On this screen page, you can delete the errors
from the memory of the controller and enable
some systems controlled by the control unit

• Left coil
• Right coil
• Left injector
• Right injector
• Stepper control
• MGCT warning light
• Lambda probe heater 1
• Lambda probe heater 2
• Injector control
• Headlights relay
• Stepper
• Coil command
• Fuel pump
• General warning light
• Secondary air EV

Diagnostic tool - Errors screen page

This display shows potential errors detected in the
vehicle (ATT) or stored in the control unit (MEM)
and it allows to check error clearing (STO).

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Electrical system V7 E5 Special-Stone

Diagnostic tool - Adjustment

This screen page is used to adjust some control
unit parameters

• Resetting
• Downloading Mem Data
• Self-adaptive parameters reset

Diagnostic tool - Electrical errors

Air pressure sensor P0105 - short circuit to positive / open circuit, short circuit to negative, signal not
valid
Error cause

• Malfunction of sensor inside the control unit

Troubleshooting

• Replace the control unit

Air temperature sensor P0110 - short circuit to positive, open circuit / short circuit to negative
Error cause

• Malfunction of sensor inside the control unit

Troubleshooting

• Replace the control unit

Error EEPROM P0601 - circuit not working

Error cause

• The instrument cluster does not indicate the presence of this error even in the ATT status

Troubleshooting

• Replace the engine control unit

Error RAM P0604 - circuit not working

Error cause

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V7 E5 Special-Stone Electrical system

• The instrument cluster does not indicate the presence of this error even in the ATT status

Troubleshooting

• Replace the engine control unit

Error ROM P0605 - circuit not working

Error cause

• The instrument cluster does not indicate the presence of this error even in the ATT status

Troubleshooting

• Replace the engine control unit

Saved data file (for safety) P1607 - filled

Error cause

• This indication appears only if the Level 2 safety has reset the engine (C gravity). The in-
strument panel does not indicate the presence of this error even in the ATT status.

Troubleshooting

• Replace the engine control unit

Sensor potentiometer throttle valve position P0120 - short circuit to positive, open circuit / short
circuit to negative
Cause of error

• Malfunction of sensor inside the control unit

Troubleshooting

• Replace the control unit

Diagnostic tool - Adjustment

Throttle positioner autodetection

• It allows the control unit to detect the closed throttle position; just press the Enter key

Reset of self-adaptive parameters

• 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.

Diagnostic tool - Reset

• Once the throttle body or the injection control unit is replaced, it is necessary to connect to
the diagnostic tool selecting FUEL INJECTION and carry out the operation "THROTTLE
POSITIONER AUTODETECTION"

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Electrical system V7 E5 Special-Stone

Dashboard

PIN:

1. CAN H line
2. High beam warning light inlet
3. Engine oil pressure sensor inlet
4. /
5. ABS Warning light control inlet
6. Ground lead
7. Ground lead
8. CAN L line
9. Instrument panel backlighting control inlet
(DRL)
[Link] sensor inlet
11./
[Link] (hazard)
[Link] ground
14./
[Link] temperature input
16./
17./
18./
[Link] panel power supply (+ 12V)
20./
[Link]-on positive (+ key)
[Link] front turn indicator control
[Link] rear turn indicator control
[Link] front turn indicator control
[Link] Rear turn indicator control
[Link] panel power supply (+ 12V)

Diagnostic tool - Electrical errors

The instrument cluster errors are detected by means of the diagnostic tool. It is therefore necessary to
connect it to the vehicle.

Error code B0008 (ALARM DISCONNECTED)

Error cause
• Occurs during the encoding of the first key connection, if the CAN line from the engine control
unit is missing, the error is activated

Identification

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V7 E5 Special-Stone Electrical system

• General alarm warning continuously on (red) and indication "ALARM DISCONNECTED" on

the display

Troubleshooting

• Check the integrity and the continuity of the cables of the CAN line between PIN 8 instrument
cluster and PIN 27 injection control unit and between PIN 1 instrument cluster and PIN 26
injection control unit
• Further check that in the CAN line is no continuity with the vehicle mass or with positive

Error code B0009 (ALARM DISCONNECTED)

Error cause

• The instrument cluster is not able to send data on the CAN line

Identification

• General alarm warning continuously on (red) and indication "ALARM DISCONNECTED" on

the display

Troubleshooting

• Check the integrity, the continuity and the absence of the cables of the CAN line between
PIN 8 instrument cluster and PIN 27 injection control unit and between PIN 1 instrument
cluster and PIN 26 injection control unit
• Further check that in the CAN line is no continuity with the vehicle mass and with positive

Error code B0300 (ALARM DISCONNECTED)

Error cause

• Occurs during the encoding of the first key connection, if the CAN line from the left light
switch control is missing, the error is activated

Identification

• General alarm warning continuously on (red) and indication "ALARM DISCONNECTED" on

the display

Troubleshooting

• Check that there is no continuity between the two cables of the CAN line; if not OK restore,
if OK check the integrity and the continuity between PIN 8 instrument cluster and PIN 4 left
light switch; if not OK restore, if OK check the integrity and the continuity between PIN 1
instrument cluster and PIN 3 left light switch; if not OK restore, if OK check that the CAN
lines are not in continuity with the vehicle ground or with positive

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Electrical system V7 E5 Special-Stone

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
Switch normally open. With oil pressure above
0.35 + / - 0.2 bar (5.1 + / - 2.9 PSI), closed circuit.
Level in electrical circuit diagram
fuel reserve and oil pressure.
Position

• Sensor: between the two heads, at the

back.
• Connector: on the sensor.

Electrical specifications

• With engine off: closed circuit (continu-

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

Pin-out

1. Voltage 12V (violet).

Diagnostic tool - Electrical errors

Error code B0001 (ALARM OIL SENSOR)
Occurs when the sensor is disconnected or faulty. When detected, the diagnostic tool shows the error
only if this is still active after having performed two TRIP followed by a third key switching OFF-ON.
Error cause

• An oil sensor fault is signalled when, with engine running, it is detected that the sensor circuit
is closed. The test is performed only once when the key is set to ON

Identification

• General alarm warning continuously on (red) and indication "ALARM OIL SENSOR" on the
display

Troubleshooting

• Check that the sensor connector is properly connected; Check the sensor connector and
the instrument panel connector (PIN 3): if they are not OK, restore. If OK, check with engine
off, continuity of the purple cable between the sensor connector and the instrument panel

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V7 E5 Special-Stone Electrical system

connector PIN 3: if not OK, restore the wiring harness, if OK check continuity between the
positive of the sensor and the vehicle ground, if not OK restore, if OK replace the sensor

Error code B0002 (ALARM OIL PRESSURE)

This alarm occurs when the engine is on and the pressure of the engine oil is low. Just above 650 rpm.
Error cause

• An oil sensor fault is signalled when, with engine running, it is detected that the sensor circuit
is open.

Identification

• General alarm warning flashing (red) and indication "ALARM OIL PRESSURE" on the dis-
play

Troubleshooting

• Check the engine and its operation before continuing with the verifications related to the
sensor. Check the sensor connector and the instrument panel connector PIN 3: if not OK
restore, if OK disconnect the sensor and check that there is no continuity between vehicle
sensor connector and vehicle ground, if not OK restore, if OK check with running engine
with disconnected sensor that there is no continuity between sensor and vehicle ground, if
not OK restore, if OK replace sensor.

AIR TEMPERATURE SENSOR

Function
Indicates the ambient air temperature to the in-
strument panel
Operation / Operating principle
NTC type sensor (resistance sensor, inversely
variable with temperature)
Level in electrical circuit diagram
Temperature sensors
Position

• Fastened to the instrument cluster sup-

port, behind the cover
• Connector: under the ignition lock

Electrical specifications

• Resistance at 0°C: 32.5 kOhm +/- 5%

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

Pin-out

1. Voltage 5V (pink)

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Electrical system V7 E5 Special-Stone

2. Ground (brown)

Diagnosis
An instrument cluster temperature sensor failure is signalled when it is detected that the sensor circuit
is open or shorted to positive/negative
Error cause

• Possible malfunction

Troubleshooting

• Check the sensor connector and the instrument panel connector (PIN 15); If they are not
OK, restore. If OK, check continuity of the pink cable between the sensor connector (wiring
harness side) and the instrument panel connector PIN 15; if it is not OK, restore the wiring
harness; if OK, check the correct sensor resistance; If not OK, replace the sensor; if OK,
with key set to ON, check if there is voltage at the sensor connector PIN 1 if not OK, replace
the instrument panel; if there is approximately 12V, restore the wiring harness, as there is
a short circuit in the battery. If there is instead 5V voltage, connect a 10 kOhm resistance to
PIN 1 of the sensor connector and to the vehicle ground connection If, with the key ON, the
voltage measured upstream of the resistance drops, replace the instrument panel. If it con-
tinues to stay at about 5 V restore the pink cable, as there is a short circuit to + 5V. In case
of short circuit to ground detected on PIN 15 of the instrument cluster connector, check
isolation from ground of the pink cable from the sensor connector; If connected to ground,
restore the cabling. If insulated from ground, check correct resistance of the sensor; if not
OK, replace the sensor; if it is OK, replace the instrument panel

Can line

Function
Allows the communication between injection control unit, instrument cluster, ABS control unit, right light
switch
Operation / Operating principle
A CAN line (Controller Area Network) is a connection between different electronic devices of a vehicle
organised like a computer network (internet). The CAN network allows to significantly simplify the layout
of the electric system and so its overall ground. With this communication line, needless duplication of

ELE SYS - 164

V7 E5 Special-Stone Electrical system

several sensors present on the motorbike has been obviated. The sensor signals are shared by the two
electronic elaboration units (instrument panel and control unit).
• Cable number reduction: The CAN line travels through a twisted cable to several nodes.
• These nodes can also isolate the errors without causing a system breakdown (FaultsCon-
fination).
• Immunity to interference: the signal travels through two cables and the signal reading is
differential (voltage difference between the two signals on both cables). If the two signals
are disturbed by an external factor, their difference remains unaltered.
• Communication speed: messages travel at a speed of 250 kbps (data arrive at nodes every
20 ms, i.e. 50 times/second).
CAN PROTOCOL (CONT. NETWORK AREA)
The communication protocol is CSMA/CD (Carrier Sense Multiple Access w/ Collision Detection).
In order to transmit, every nod must first check that the BUS (the connection among all devices) is free
before attempting to send a message with BUS (Carrier Sense).
If during this period there is no activity on BUS, every nod has the same chance to send a message
(Multiple Access). If two nodes start transmitting simultaneously, the nodes recognise the "colli-
sion" (Collision Detection) and initiate an exchange action based on message priority (messages remain
unaltered during exchange and there is no delay for high priority messages).
CAN protocol is based on messages and not on addresses. The message itself is divided into several
parts (frames), each of which has a meaning: message priority, data contained, error detection, recep-
tion confirmation, etc.
Every network nod receives all the messages sent through the BUS (with reception confirmation or error
messages) and each nod decides if the message is to be processed or rejected. Besides, every nod
can request information from the other nodes (RTR = Remote Transmit Request).
Level in electrical circuit diagram
CAN Line
Pin-out
• Between PIN 26 and 27 of the engine control unit
• Between PIN 1 and 8 of the instrument panel
• Between PIN 5 and 6 of the ABS control unit
• Between PIN 3 and 4 of the left light switch
• Between PIN 1 and 2 of the bluedash preparation
Diagnostic tool - Electrical errors
CAN line U0001 NO SIGNAL (BUS OFF) - Bus Off.
Error cause
• No communication on CAN line (PIN 26 and/or PIN 27): problem on the whole network (for
example, battery cut-off or short circuited or shorted to ground).
Troubleshooting

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Electrical system V7 E5 Special-Stone

• Check the engine control unit connector if not OK, restore; if OK, check the ground insulation
of the two CAN lines from PIN 26 and PIN 27 of the engine control unit connector if not OK,
restore wiring harness; if OK, check the continuity of the two CAN lines from the engine
control unit connector to the instrument panel connector if not OK restore cabling, if OK
check that the two lines are not short circuited to positive testing from each of the connectors
(engine control unit, instrument panel connector) with connector at a time disconnected and
turning the key to the ON position If not OK, restore; if OK, replace the engine control unit.

CAN line U0002 MUTE NODE - Mute node.

Error cause

• The engine control unit is not able to send CAN signals, but to receive signals from the
instrument cluster, ABS control unit, right light switch, it might be necessary to replace the
engine control unit.

Troubleshooting

• Replace the engine control unit.

ABS control unit "NO NODE" U0121 - No node/frame counter

Error cause

• Missing communication of the ABS control unit to the CAN line

Troubleshooting

• Disconnect the ABS control unit connector and check that there is no dirty, oxidised or dam-
aged PIN; if not ok restore, if ok check continuity between PIN 5 and 6 ABS control unit and
PIN 26 and 27 engine control unit; if not ok restore, if ok check continuity between PIN 5
and 6 ABS control unit and PIN 1 and 8 of the instrument cluster; if not ok restore, if ok check
continuity between PIN 5 and 6 ABS control unit and PIN 3 and 4 of the left light switch; if
not ok restore, if ok check that there is no continuity between the two cables of the CAN line
(L and H); if not ok restore, if ok check that there is no continuity between vehicle ground
and the battery positive; if not ok restore, if ok replace the ABS control unit

CAN line D347 - transmission time-out

Error cause

• Electric malfunction. Open circuit, short circuit to negative, short circuit to positive of one or
both wires of CAN line

Troubleshooting

• Replace the wiring harness

CAN line 5E11 - Bus Off

Error cause

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V7 E5 Special-Stone Electrical system

• Electric malfunction. Open circuit, short circuit to negative, short circuit to positive of one or
both wires of CAN line

Troubleshooting

• Replace the wiring harness

CAN line 5E16 - vehicle code message absent

Error cause

• Missing reception of CAN line to engine control unit

Troubleshooting

• Check the control unit software version; if not ok restore, if ok remove the battery and check
continuity of the CAN line; if not ok restore, if ok reconnect the battery and check that there
is no continuity between CAN line to positive and/or negative; if not ok restore, if ok check
and if necessary replace the ABS control unit

Diagnostics tool - Logic errors

Rear wheel radius acquisition P1800 - signal not valid
Error cause

• CAN error during acquisition

Troubleshooting

• In case of CAN error during acquisition, system warns that the procedure can not be com-
pleted due to a communication problem on the CAN line. In case of invalid value, it means
that on key-ON an error of transcription occurred - from the non-volatile memory (EEPROM)
to the volatile one (RAM) - of the value concerning the rear wheel radius. In this case the
default value is used.

CAN line 5E1F - incorrect vehicle code

Error cause

• The ABS control unit was installed in a wrong vehicle

Troubleshooting

• Replace the control unit

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INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

V7 E5 Special-Stone Engine from vehicle

FRAME
Pos. Description Type Quantity Torque Notes
1 Screws fastening the tank support M8 2 25 Nm (18.44 lbf ft) -
buffers to the frame
2 Front cradle fixing screws M10 4 50 Nm (36.88 lb ft) Pre-permeated
3 Screw fastening the stand cross- M10 1 50 Nm (36.88 lb ft) Pre-permeated
piece to the cradles
4 Battery holder plate fixing screw M8 4 25 Nm (18.44 lbf ft) Pre-permeated
5 Screws fastening engine/gearbox to M10 3 50 Nm (36.88 lb ft) -
frame
6 Screws fastening gearbox to frame M10 2 50 Nm (36.88 lb ft) -
7 Rear grab handle fastening screws M6 2 10 Nm (7.38 lbf ft) -

Vehicle preparation

• To arrange for the removal of the engine block, you must first remove the saddle, fuel tank,
side fairings and the battery

• From the front, secure the vehicle with belts attached to a hoist
• Position a centre stand under the engine sump
• Position an engine support so as not to damage the rubber bellows of the drive shaft

ENG VE - 169
Engine from vehicle V7 E5 Special-Stone

Removing the engine from the vehicle

• Remove the two fixing screws of the

collector cover and remove the latter
NOTE
REPEAT THE OPERATION FOR THE RIGHT COVER AS
WELL

• Disconnect the cylinder temperature

sensor connector.
NOTE
REPEAT THIS OPERATION ON THE OPPOSITE SIDE

NOTE
THE OPERATIONS FOR REMOVING THE EXHAUST TERMINAL, APPLY TO BOTH ENDS
• Remove the three fixing screws of the
silencer guard

ENG VE - 170
V7 E5 Special-Stone Engine from vehicle

• Remove the silencer guard, sliding it

toward the front of the vehicle

• Loosen the clamp between the silencer

and manifold

• Remove the screw that fastens the si-

lencer to the support bracket

• Slide and remove the silencer from the

collector

ENG VE - 171
Engine from vehicle V7 E5 Special-Stone

• Remove the two starter motor cover

fixing screws

• Remove the starter motor cover

• Disconnect from their support the con-

nectors of the lambda probe wiring har-
ness.
• Using a screwdriver, press the tab and
pull the wiring harness downward at
the same time

• Disconnect the connectors of the lamb-

da probe wiring harness
NOTE
REPEAT THIS OPERATION ON THE OPPOSITE SIDE

ENG VE - 172
V7 E5 Special-Stone Engine from vehicle

• Remove the nuts and the correspond-

ing fixing washers of the exhaust mani-
folds

• Remove the exhaust manifolds at the

same time

• Disconnect the clutch cable from the lever and free it from the cable grommet

• Undo the screws fixing the spark plug

covers, remove the covers

ENG VE - 173
Engine from vehicle V7 E5 Special-Stone

• Disconnect the spark plugs tubes

• Remove the screws fixing the manifold

to the cylinder heads

• Remove the fixing screw of the engine

oil pressure sensor cover
• Remove the engine oil pressure sen-
sor cover

• Remove the fixing screw (1) and then

remove the engine oil pressure sensor

ENG VE - 174
V7 E5 Special-Stone Engine from vehicle

• Remove the fixing nut of the engine

ground cable

• Remove the fixing nut of the power

supply cable located on the starter mo-
tor. Then remove the cable

• Disconnect the starter motor faston

• Remove the two starter motor fixing

screws

ENG VE - 175
Engine from vehicle V7 E5 Special-Stone

• Remove the starter motor complete

with support bracket for the cover

• Disconnect the secondary air system

pipes from the cylinder heads

• Remove the clamp fixing the flywheel

wiring harness to the brake pipes

• Remove the screws that fasten the

voltage regulator to the chassis
• Remove the regulator an the horn from
the vehicle

ENG VE - 176
V7 E5 Special-Stone Engine from vehicle

• Disconnect the flywheel/alternator

connectors and release them from the
passage in the frame

• Remove the fixing screws of the rider

right footrest / rear brake pump assem-
bly

• Remove the rider right footrest / rear

brake pump assembly from the chassis
cradle and retrieve the two bushings

ENG VE - 177
Engine from vehicle V7 E5 Special-Stone

• Disconnect the side stand sensor con-

nector and then remove the wiring har-
ness from the lower side of the vehicle

• Disconnect the uniball that connects

the gear lever transmission to the ve-
hicle's gearbox

• Disconnect the uniball that connects

the gear lever to the gear lever trans-
mission

• Remove the clamp and disconnect the

pipe that connects the tank to the can-
ister. Remove the pipe by extracting it
from the lower side of the vehicle

ENG VE - 178
V7 E5 Special-Stone Engine from vehicle

• Remove the clamp and disconnect the

pipe that connects the valve to the can-
ister. Remove the pipe by extracting it
from the lower side of the vehicle

• Remove the cradle lower fixing screw

• Repeat this operation on the opposite
side.

• Remove the front screws fixing the cra-

dle, making sure to recover the asso-
ciated nuts and washers
• Repeat this operation on the opposite
side.

• Remove the cradle rear fixing screw

• Repeat this operation on the opposite
side.

ENG VE - 179
Engine from vehicle V7 E5 Special-Stone

• Remove the cradle from the vehicle's

chassis together with the canister and
the left footrest/gear lever assembly

• Remove the rear brake calliper and the

ABS sensor

• Remove the cable grommet plate

placed under the swingarm

• Disconnect the rear ABS sensor, rear

brake switch and neutral sensor con-
nectors
• Move the rear brake system complete

ENG VE - 180
V7 E5 Special-Stone Engine from vehicle

• Secure the chassis on a lifting device

and place a pantograph stand under
the oil sump

• Remove the pins fastening the gear-

box to the chassis, making sure to re-
trieve the associated nuts and washers

• Remove the lower fixing screws of the

rear shock absorbers and move them
from the support pins on the swing-
arm//bevel gear

• Slightly lift the frame and disconnect

the blow-by pipe

ENG VE - 181
Engine from vehicle V7 E5 Special-Stone

• Disconnect the gear sensor connector

• Lift the frame sufficiently and remove

the engine complete with swingarm

ENG VE - 182
INDEX OF TOPICS

ENGINE ENG
Engine V7 E5 Special-Stone

TO CONSULT THE CHAPTER ABOUT THE ENGINE AND ITS COMPONENTS PLEASE REFER TO
THE APPROPRIATE MANUAL:
"MSS Engine 850 Euro 5"

ENG - 184
INDEX OF TOPICS

POWER SUPPLY P SUPP

Power supply V7 E5 Special-Stone

Circuit diagram

key:

1. Fuel tank
2. Fuel pump
3. Canister
4. Throttle body
5. Fuel delivery pipes
6. Fuel vapour recovery pipe
7. Check valve
8. Breather pipe

Injection

P SUPP - 186
V7 E5 Special-Stone Power supply

Diagram

Key:

1. Control unit position

2. Ignition switch
3. Battery
4. Fuel pump
5. Coils
6. Instrument cluster
7. air temperature sensor
8. Throttle valve position sensor
9. Injectors
[Link] temperature sensor
[Link] probe
[Link] stand switch

P SUPP - 187
Power supply V7 E5 Special-Stone

[Link] sensor
[Link] sensor

P SUPP - 188
INDEX OF TOPICS

SUSPENSIONS SUSP
Suspensions V7 E5 Special-Stone

Handlebar

HANDLEBAR AND CONTROLS

Pos. Description Type Quantity Torque Notes
1 Screw fixing handlebar support U-bolts to M10 2 50 Nm (36.88 lb ft) -
steering plate
2 Handlebar U-bolt fastener screws M8 4 25 Nm (18.44 lbf ft) -
3 Mirror fixing M10 2 Manual -
- Light switch fastening screws SWP 5 2 1.5 Nm (1.11 lb ft) -
- Throttle cable cover fastening screws M5 3 6 Nm (4.43 lbf ft) -

Removing

(SPECIAL/STONE)

• Remove the light switches

• Unscrew and remove the four fasten-
ing screws (1)
• Remove the upper U-bolt (2)
• Remove the handlebar (3)

SUSP - 190
V7 E5 Special-Stone Suspensions

Front fork

FRONT SUSPENSION - STEERING

Pos. Description Type Quantity Torque Notes
1 Screws fastening stanchion on upper plate M8x35 4 25 Nm (18.44 lbf ft) -
2 Steering head fastening bushing - 1 100 Nm (73.76 lb ft) -
3 Steering headstock lock nut - 1 50 Nm (36.88 lb ft) Pre-torque 60 Nm (44.25
lb ft)
4 Headstock counter-lock ring - 1 Manual -
5 Calliper bracket fixing screws M6x30 2 10 Nm (7.38 lbf ft) -

SUSP - 191
Suspensions V7 E5 Special-Stone

Pos. Description Type Quantity Torque Notes

6 Connector plate fastening screw M6x16 1 10 Nm (7.38 lbf ft) -
7 Screws fastening stanchion on lower plate M10 2 45 Nm (33.19 lb ft) -
8 Pumping unit fastening screw M10 2 50 Nm (36.88 lb ft) -

Diagram

Key:

1. Screw
2. Washer
3. Screw
4. Left sleeve
5. Upper bushing
6. Washer
7. Seal ring
8. Retainer ring
9. Dust guard
[Link]
[Link] bushing
[Link]
[Link] spring
[Link] pumping member
[Link]
[Link]

SUSP - 192
V7 E5 Special-Stone Suspensions

[Link] cap
18.O-ring

Removing the fork legs

The following procedure is only shown from one side of the vehicle, but is valid for both stan-
chions
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.

• Remove the front mudguard.

• 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.

Draining oil

To drain out the oil follow these steps.

• Remove the stanchion.

SUSP - 193
Suspensions V7 E5 Special-Stone

• 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.

• 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.

SUSP - 194
V7 E5 Special-Stone Suspensions

• 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.

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.

SUSP - 195
Suspensions V7 E5 Special-Stone

• 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.

• 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.

SUSP - 196
V7 E5 Special-Stone Suspensions

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.

• 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.

SUSP - 197
Suspensions V7 E5 Special-Stone

• Insert the bearing tube in the wheel

holder and push it until it stops.

• 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.

SUSP - 198
V7 E5 Special-Stone Suspensions

• 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.

Filling oil

• Place the sleeve upright in a vice fitted

with protection shoes.
• Compress the sleeve in the stanchion.
• Pour part of the fork oil into the sleeve.
• Wait a few 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
Oil level (from sleeve rim, without the spring
and with stem at end of stroke)
120 +/- 1.5 mm (4.72 +/- 0.06 in)
Oil quantity (for each stanchion)
385 +/- 2 cc (23.49 +/- 0.12 cu in)

SUSP - 199
Suspensions V7 E5 Special-Stone

• 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 - 200
V7 E5 Special-Stone Suspensions

Steering bearing

FRONT SUSPENSION - STEERING

Pos. Description Type Quantity Torque Notes
1 Screws fastening stanchion on upper plate M8x35 4 25 Nm (18.44 lbf ft) -
2 Steering head fastening bushing - 1 100 Nm (73.76 lb ft) -
3 Steering headstock lock nut - 1 50 Nm (36.88 lb ft) Pre-torque 60 Nm (44.25
lb ft)
4 Headstock counter-lock ring - 1 Manual -
5 Calliper bracket fixing screws M6x30 2 10 Nm (7.38 lbf ft) -

SUSP - 201
Suspensions V7 E5 Special-Stone

Pos. Description Type Quantity Torque Notes

6 Connector plate fastening screw M6x16 1 10 Nm (7.38 lbf ft) -
7 Screws fastening stanchion on lower plate M10 2 45 Nm (33.19 lb ft) -
8 Pumping unit fastening screw M10 2 50 Nm (36.88 lb ft) -

Adjusting play

• Place the vehicle so that the front wheel is off the ground.
• Carry out a handlebar rotation test, using a dynamometer at the hand grip external end.
• Adjust if clearance is detected.
NOTE
THE STEERING COLUMN RESISTANCE TO ROTATION MUST BE PERFORMED IN THE TWO
OPPOSITE ROTATION DIRECTIONS.
• Remove temporarily, moving the in-
strument cluster, handlebars (com-
plete with column switch and brake and
clutch levers) and the upper steering
plate towards the front of the vehicle
• Remove the safety washer (1)

• Remove the steering counter-lock ring

(2) using the special tool

• Remove the rubber spacer (3)

SUSP - 202
V7 E5 Special-Stone Suspensions

• Unscrew the lower ring nut in order to

repeat the steering play adjustment
procedure correctly.

• Pre-tighten the lower ring nut to the torque of 60 Nm (44.25 lb ft).

• Steer repeatedly completely left and completely right to allow the bearings to settle.
• Loosen the ring nut.
• Check again the pre-tightening torque and then tighten the ring nut again to a torque of 50
+/- 5 Nm (36.88 +/- 3.69 lb ft).
• Steer completely left and completely right and check that the steering rotates smoothly and
without excessive resistance.
• If any problems are noted, repeat the procedures described above.

Specific tooling
AP8140190 Steering tightening tool

• Reposition the rubber spacer (3)

• Insert and tighten the steering counter-lock ring (2) so that the grooves are aligned
• Reposition the safety washer (1)
• Refit the upper steering plate, handlebars and instrument cluster

Rear

SUSP - 203
Suspensions V7 E5 Special-Stone

Shock absorbers

REAR SHOCK ABSORBERS

Pos. Description Type Quantity Torque Notes
1 Rear shock absorber upper/lower fixing M6 4 10 Nm (7.38 lbf ft) Pre-permeated
screws
2 Pin fastening the shock absorber to the gear- M12 2 35 Nm (25.81 lb ft) Pre-permeated
box/swingarm

Removing

(SPECIAL/STONE)

• Remove the silencers

REAR RIGHT SHOCK ABSORBER

• Unscrew and remove the two screws

(1)
• Retrieve the two bushings (2)

SUSP - 204
V7 E5 Special-Stone Suspensions

• Remove the RH rear shock absorber

(3)

REAR LEFT SHOCK ABSORBER

• Unscrew and remove the two screws

(1)
• Retrieve the two bushings (2)

• Remove the rear shock absorber (3)

SUSP - 205
INDEX OF TOPICS

CHASSIS CHAS
V7 E5 Special-Stone Chassis

Wheels

Front wheel

(SPECIAL)

(STONE)

CHAS - 207
Chassis V7 E5 Special-Stone

FRONT WHEEL
Pos. Description Type Quantity Torque Notes
1 Wheel axle M18 1 80 Nm (59.00 lb ft) -
2 Front brake disc fixing screws M8 6 25 Nm (18.44 lbf ft) Loctite 243
3 ABS-sensor fixing stud bolt M5 1 6 Nm (4.43 lbf ft) Pre-permeated
4 Cable grommet nut M6 1 6 Nm (4.43 lbf ft) -

Removal

• 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;
• Working on the right side of the motor-
cycle, remove the cap from the pin;

• Loosen the two wheel pin locking

screws;

• Unscrew and remove the wheel pin;

CHAS - 208
V7 E5 Special-Stone Chassis

• Working on the opposite side, remove

the left spacer;
NOTE
DURING REFITTING, PAY ATTENTION TO THE CORRECT
POSITIONING OF THE SPACER WHICH MUST BE INSER-
TED IN THE DUST SEAL UNTIL IT REACHES THE BEAR-
ING

• Working on the opposite side, remove

the left spacer;
NOTE
DURING REFITTING, PAY ATTENTION TO THE CORRECT
POSITIONING OF THE SPACER WHICH MUST BE INSER-
TED IN THE DUST SEAL UNTIL IT REACHES THE BEAR-
ING

• Remove the dust seal from both sides

• Using a generic bearing extractor remove the bearings from both sides

Rear wheel

(SPECIAL)

CHAS - 209
Chassis V7 E5 Special-Stone

(STONE)

REAR WHEEL
Pos. Description Type Quantity Torque Notes
1 Rear brake disc fastening screws M8 6 25 Nm (18.44 lbf ft) Loctite 243
2 Rear wheel axle fastener pin + nut M20 1 100 Nm (73.77 lb ft) -
3 ABS sensor fixing screw M6 1 6 Nm (4.43 lbf ft) Loctite 243

CHAS - 210
V7 E5 Special-Stone Chassis

Rimozione

• Remove the screw fixing the right-hand

rear right shock absorber and pull it
from the pin on the drive shaft

• Remove the screw fixing the left-hand

rear shock absorber and remove it
from the pin

• Using a jack, lift the rear of the motor-

cycle.
• Unscrew the rear fixing screw of the
rear brake calliper support

• Unscrew the wheel axle nut, making

sure to take the washer from the left
side and pull the pin itself from the right
side.

CHAS - 211
Chassis V7 E5 Special-Stone

• Remove the rear brake calliper support

• Collect the spacer

NOTE
DURING REFITTING, PAY ATTENTION TO THE CORRECT
POSITIONING OF THE SPACER WHICH MUST BE INSER-
TED IN THE DUST SEAL UNTIL IT REACHES THE BEAR-
ING

• Remove the rear wheel

• Remove and if necessary replace the

six flexible couplings

CHAS - 212
V7 E5 Special-Stone Chassis

• Remove the dust seal

• Remove the locking Seeger ring of the

bearing from the side where the en-
coder/brake disc wheel is present

• Using a generic bearing extractor remove the bearings from both sides

Spoke tension adjustment

CAUTION

DO NOT ADJUST THE TENSION OF THE WHEEL SPOKES WITH TIRES FITTED ON THE WHEEL
RIM, AS THIS COULD CAUSE BREAKING OF THE NIPPLE GUARDS AND RESULTING IN HOLES
OF THE AIR CHAMBER.
IT IS IMPORTANT TO LOCK THE ROTATION OF ALL NIPPLES.
LOOSENING THE NIPPLE MODIFIES THE TENSION OF THE WHEEL SPOKES COMPROMISING
THE SAFETY OF THE WHEEL RIMS AND THE STABILITY OF THE VEHICLE
• Remove the wheel
• Remove the tires, the air chamber and the nipple guards;
• Locate the wheel spokes (1) to be tightened;
• Operate on the nipple (2) to adjust the relative spoke tension (1);

- screw to tighten the spoke;

- unscrew to loose the spoke;

• The indicative tightening torque of the nipples is:

- front wheel 3 Nm (2.21 lb ft)

- rear wheel 4 Nm (2.95 lb ft).

• Repeat the operation for all spokes by proceeding in successive order;

CHAS - 213
Chassis V7 E5 Special-Stone

• After having adjusted the tension of the wheel spokes, check the axial and radial clearance
of the wheel rim.
CAUTION

DO NOT ADJUST THE TENSION OF THE WHEEL SPOKES WITH TIRES FITTED ON THE WHEEL
RIM, AS THIS COULD CAUSE BREAKING OF THE NIPPLE GUARDS AND RESULTING IN HOLES
OF THE AIR CHAMBER.
IT IS IMPORTANT TO LOCK THE ROTATION OF ALL NIPPLES.
LOOSENING THE NIPPLE MODIFIES THE TENSION OF THE WHEEL SPOKES COMPROMISING
THE SAFETY OF THE WHEEL RIMS AND THE STABILITY OF THE VEHICLE

Swinging arm

SWINGARM
Pos. Description Type Quantity Torque Notes
1 Pins fixing swingarm to gearbox - 2 - Manual
2 Counter-nuts fixing swingarm to - 2 50 Nm (36.88 lb ft) -
gearbox
3 Rubber bellows torx fixing screws - 3 6 Nm (4.43 lbf ft) -

CHAS - 214
V7 E5 Special-Stone Chassis

Removing

• Remove the mufflers, the rear wheel,

and the brake calliper support com-
plete with clamp / ABS sensor, and
disconnect the shock absorbers from
the support pins.
• Remove the fixing nut of the cable
grommet plate and disconnect it from
the swingarm

• Cut the sealing clamp and lift the fold-

ing
CAUTION
PAY ATTENTION NOT TO CUT AND DAMAGE THE RUB-
BER FOLDING

• Unscrew the nuts on both sides of the

swingarm

• Loosen the pins so that the oscillating

swingarm can be removed from the
gearbox.

CHAS - 215
Chassis V7 E5 Special-Stone

• Remove the complete swingarm from

the gearbox

• Remove the three screws (1) to re-

move the folding (2) complete with re-
taining ring (3)

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 sleeve outer toothing and internal grooves are not damaged.

Removing

• Remove the rear wheel

• Remove the swingarm
• Strike a few times with a mallet to re-
move the cardan shaft (1)

CHAS - 216
V7 E5 Special-Stone Chassis

Checking

Carefully check:
The splines on the cardan shaft (1) must be intact,
free from grain or dents.
Check that the joints (2) are not hardened or ex-
cessively loose, otherwise replace it.

In the figure are shown two worn toothing profiles:

• Profile (3) shows acceptable wear, the

cardan shaft should not be replaced.
• Profile (4) shows unacceptable wear,
the cardan shaft must be replaced.

Bevel gears

CHAS - 217
Chassis V7 E5 Special-Stone

BEVEL GEAR
Pos. Description Type Quantity Torque Notes
1 Pinion unit fixing nut - OPTION 01 M25 1 100 Nm (73.76 lb ft) Loct. 243
2 Pinion unit fixing lock nut - OPTION M25 1 20 Nm (14.75 lbf ft) Loct. 243
01
3 Pinion unit fixing nut - OPTION 02 M25 1 100 Nm (73.76 lb ft) Loct. 243 + Nut re-
bating on hollow
pinion
4 Oil drainage plug M10 1 30 Nm (22.13 lb ft) -
5 Oil load cap M12 1 25 Nm (18.44 lbf ft) -
6 Ring nut - 1 100 Nm (118.01 lbf ft) Loct. 243 + Riveting
on the splash guard
hub
7 Bleeder cap - 1 10 Nm (7.38 lbf ft) -
8 Gearbox cover fastening screws M8x25 8 25 Nm (18.44 lbf ft) -
CAUTION
SINCE THE BEVEL GEAR IS A SAFETY COMPONENT, IT IS STRICTLY FORBIDDEN TO PER-
FORM ANY PINION/SPROCKET CLEARANCE ADJUSTMENTS FOR THE ENTIRE DURATION OF
THE COMPONENT'S SERVICE LIFE. IF THE CLEARANCE IS NOT WITHIN THE REQUIRED TOL-
ERANCE, THE ENTIRE BOX WILL HAVE TO BE REPLACED.
IF OIL LEAKAGES ARE DETECTED ON THE SPROCKET SIDE, REPLACE THE OIL SEALS AC-
CORDING TO THE DESCRIPTION BELOW.

Removing

• Loosen and remove the screws (1).

• Loosen and remove the screws (2).

CHAS - 218
V7 E5 Special-Stone Chassis

• Remove the gearbox (3).

Replacement of the oil seal on the wheel hub with bevel gear mounted on the vehicle

• Firmly screw a small self-tapping

screw (M5-M6) on the oil seal

• Use a clamp to grab the screw and re-

move the oil seal from the wheel hub
seat

CHAS - 219
Chassis V7 E5 Special-Stone

• Insert a new oil seal in the specific seat,

tap it inside with a tube with a slightly
smaller diameter than the external di-
ameter of the oil seal
• The oil seal is inserted when it reaches
the end

Removal
CAUTION
CARRY OUT OIL DRAINING AND PROCEED WITH THE REMOVAL OF THE BREATHER BEFORE
DISASSEMBLING THE GEARBOX.
• Using the specific tool, clamp the com-
plete gearbox in the vice.
• Loosen and remove the 8 fastener
screws of the flange.

Specific tooling
021000Y Bevel gear set mounting

• Use threaded stud bolts as a guide and

remove the flange.

CHAS - 220
V7 E5 Special-Stone Chassis

• Remove the ring gear axle thickness.

• Remove the inner spacer.

• Remove the bearing's roller cage.

• Using a suitable tool, disengage the ra-

dial snap ring and remove it.

CHAS - 221
Chassis V7 E5 Special-Stone

• Heat the outer track seat of the roller

bearing using an air heater.

• Insert the special tool under the washer

and screw the cursor.

Specific tooling
001467Y036 Bearing internal cup extractor

• Insert a bush with a suitable diameter

on the specific tool and tighten the nut
keeping the extractor locked.

• Remove the outer track of the roller

bearing.

CHAS - 222
V7 E5 Special-Stone Chassis

• Remove the washer.

• Remove the sealing ring.

• When reassembling use a new ring.
CAUTION
DURING REASSEMBLY BE CAREFUL, AS THE SEALING
RING MUST BE INSERTED UNTIL IT STOPS, USING THE
SPECIFIC PRESS-FIT PAD.

• Operating from the internal side of the

flange, remove the hub's internal oil
seal by tapping it with a punch

• Using the protective jaws, block the

complete flange in the vice and remove
the radial stop ring using a specific tool.

CHAS - 223
Chassis V7 E5 Special-Stone

• Unscrew the ring nut, using the special

tool, to loose the riveting.
• After unscrewing the ring nut to the end
of the thread, re-tighten it until it stops
in such a way as to create the space
between the ring nut and the shoulder
washer.

Specific tooling
020999Y Crown counter- lock ring wrench
• Insert the special tool under the shoul-
der washer and screw the cursor.

Specific tooling
GU19907000 Internal bearing ring extractor

• Remove the inner track of the roller

bearing.

• Remove the shoulder washer.

CHAS - 224
V7 E5 Special-Stone Chassis

• Remove the ring nut.

• Remove the crown gear.

• Remove the gearbox flange from the

splash guard hub.

• Remove the O-ring.

• When reassembling use a new O-ring.

CAUTION
PAY SPECIAL ATTENTION TO THE CORRECT REMOVAL PROCEDURE OF THE OIL SEAL TO
AVOID THE DAMAGE OF THE STEEL SHEET UNDER THE OIL SEALER.

CHAS - 225
Chassis V7 E5 Special-Stone

• Use a small self-tapping screw (M5-

M6) and screw it slightly to grip on the
oil seal.
CAUTION
DO NOT TIGHTEN THE SCREW AS IT COULD DAMAGE
THE UNDERLYING THIN SHEET.

• Using a clamp to remove the oil seal

from the seat, using a Teflon or wood-
en support to avoid damaging the
flange of the gearbox.

• Check the correct integrity of the un-

derlying thin sheet

CAUTION
IF THE THIN SHEET IS DAMAGED, THE FLANGE TOGETH-
ER WITH THE BEARING MUST BE REPLACED, AS INDI-
CATED

CHAS - 226
V7 E5 Special-Stone Chassis

• Heat the outer area of the pinion bear-

ings holder case
• Using the special tool, loose and re-
move the pinion bearings holder case.

Specific tooling
020998Y Pinion case wrench

• Using the specific tool, clamp the as-

sembly in the vice and lift the nut again
before removing it.

Specific tooling
021000Y Bevel gear set mounting

• Loosen the pinion bearings holder

case locking nut and remove it

• Remove the spacer closing bearings.

CHAS - 227
Chassis V7 E5 Special-Stone

• Remove the sealing ring.

• Remove the O-ring.

Checking

• Dopo il montaggio della scatola, è necessario verificare il gioco tra pignone e corona. Bloc-
care in morsa il pignone e installare un comparatore mediante un supporto idoneo. Il
tastatore del comparatore deve appoggiarsi all'estremità esterna di un dente posizionato a
90°.

Characteristic
Gioco massimo ammesso
0.08-0.2 mm (0.059-0.147 in)

• Nel caso in cui il gioco misurato risulti

discordante rispetto ai valori ammessi,
procedere alla correzione mediante
selezione e sostituzione di in adeguato
spessore asse corona.

CHAS - 228
V7 E5 Special-Stone Chassis

Assembling

• Insert the new internal O-ring in the

pinion unit.

• Insert a new seal ring until it stops

• Insert the bearings closing spacer pay-

ing attention that the chamfer is placed
in contact with the O-ring.

• After having placed a new nut, using

the specific tool, lock the assembly of
the pinion bearing support case in the
vice and tighten the nut to the prescri-
bed torque.

Specific tooling
021000Y Bevel gear set mounting

CHAS - 229
Chassis V7 E5 Special-Stone

• Rivet the nut at the groove on the pin-

ion.

CAUTION
CAREFULLY CLEAN THE THREAD OF THE GEARBOX FROM LOCTITE RESIDUES BEFORE IN-
SERTING THE PINION BEARING SUPPORT CASE AGAIN.
• Using the protective jaws, block the
gearbox in vice
• Apply the loctite along the entire cir-
cumference, for a length of 3 threads
and, using the specific tool, tighten the
pinion bearing holder case to the speci-
fied torque.

Specific tooling
020998Y Pinion case wrench
• Using the special tool, insert a new seal
ring on the cover.

Specific tooling
021005Y Bevel gear cover oil seal punch

• On the opposite side of the cover, in-

sert a new O-ring.

CHAS - 230
V7 E5 Special-Stone Chassis

• Place the gearbox flange on the splash

guard hub.

• Place a new ring nut and using the spe-

cific tool tighten it to the prescribed
torque.

Specific tooling
020999Y Crown counter- lock ring wrench

• Reattach the ring nut in two opposite

points, in correspondence with the
grooves on the hub.

• Insert the shoulder washer.

CHAS - 231
Chassis V7 E5 Special-Stone

• Using the specific tool, put it in a press

and insert the inner track of the roller
bearing.

Specific tooling
GU19927900 Punch for pressing the ring in-
side the bearing

• Insert the radial snap ring.

• Using the specific tool, fit the internal

oil seal of the bevel gear hub, bringing
it to the end

Specific tooling
020359S 42 x 47 mm punch

• Place the flat washer on the gearbox.

CHAS - 232
V7 E5 Special-Stone Chassis

• Insert a new sealing ring on the gear-

box using the specific tool, paying at-
tention to the direction of assembly.

Specific tooling
021003Y Bevel gear oil seal punch

• Using the specific tool, put it in a press

and insert the outer track of the roller
bearing until it stops.

Specific tooling
020360S Adaptor 52x54 mm

• Insert the radial snap ring.

• Insert the roller cage.

CHAS - 233
Chassis V7 E5 Special-Stone

• Before proceeding with the assembly

of the inner spacer, clean it thoroughly
with an oil-soaked cloth.

• Insert the inner spacer until it stops.

• Reposition the crown axle thickness.

NOTE
THE THICKNESS HAS A UNIQUE POSITION IN THE BOX.
PAY ATTENTION TO THE CORRECT POSITION BY
CHECKING THE CORRESPONDENCE OF THE HOLES
WITH THE FASTENING SCREWS.

CAUTION
CAREFULLY CLEAN THE THREADS OF THE GEARBOX FROM LOCTITE RESIDUES BEFORE
INSERTING THE FLANGE AGAIN.
• Insert the centring pins and reposition
the complete flange in its seat in the
gearbox.

CHAS - 234
V7 E5 Special-Stone Chassis

• Insert the fixing screws of the flange

and tighten it to the prescribed torque
operating diagonally with the indicated
sequence..

• After blowing the breather with com-

pressed air, carefully remove any oil
residues and check its correct func-
tioning, put it in its seat again and tight-
en it to the prescribed torque.
CAUTION
DURING REPLACEMENT, USE A NEW SEALING GASKET.

Installing

• Insert the bevel gear (1) on the swing-

arm

• Insert and tighten the fastening screws

(2) to the prescribed torque

CHAS - 235
Chassis V7 E5 Special-Stone

• Insert and tighten the fastening screws

(3) to the prescribed torque

• Effettuare il riempimento olio seguendo quanto riportato nel capitolo "Manutenzione / Olio
trasmissione / Sostituzione"

See also
Replacement

Exhaust

EXHAUST SYSTEM
Pos. Description Type Quantity Torque Notes
1 Fastening the exhaust pipe to the en- M8 4 25 Nm (18.44 lbf ft) -
gine
2 Fastening the exhaust pipe to the si- M8 2 25 Nm (18.44 lbf ft) -
lencer
3 Lambda probes fastener M12x1.25 2 25 Nm (18.44 lbf ft) -
4 Fastening the silencers to the sup- M8 6 25 Nm (18.44 lbf ft) -
port
5 Fastening the RH/LH manifold heat M6 2 8 Nm (5.9 lb ft) -
shield
6 RH/LH manifold heat shield clamp - 2 3.5 Nm (2.58 lb ft) -

CHAS - 236
V7 E5 Special-Stone Chassis

Pos. Description Type Quantity Torque Notes

7 Fastening the RH/LH silencer heat M6 4 8 Nm (5.9 lbf ft) -
shield
8 Fastening the silencer to the support M8 4 25 Nm (18.44 lbf ft) -
on the chassis

Key:

1. Right exhaust manifold

2. Left exhaust manifold
3. Lambda probe
4. Lambda probe
5. Left manifold protection
6. Right manifold protection
7. Exhaust gasket
8. Nut
9. Washer
[Link]
[Link]
[Link]
[Link] spacer
[Link]
[Link]
[Link] plate
[Link]
[Link]

CHAS - 237
Chassis V7 E5 Special-Stone

[Link] silencer
[Link] silencer
[Link] silencer support bracket
[Link] silencer support bracket
[Link]
[Link]
[Link]
[Link] ring
[Link]
[Link]
[Link]
[Link] silencer protection
[Link] silencer protection
[Link] cover

Removing the tail pipe

• Slide and remove the silencer from the

collector

NOTE
THE OPERATIONS FOR REMOVING THE EXHAUST TERMINAL, APPLY TO BOTH ENDS

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.
NOTE
THE OPERATIONS FOR REMOVING THE EXHAUST TERMINAL, APPLY TO BOTH ENDS

CHAS - 238
V7 E5 Special-Stone Chassis

• Remove the three fixing screws of the

silencer guard

• Remove the silencer guard, sliding it

toward the front of the vehicle

• Loosen the clamp between the silencer

and manifold

CHAS - 239
Chassis V7 E5 Special-Stone

• Remove the screw that fastens the si-

lencer to the support bracket

• Slide and remove the silencer from the

collector

Removing the exhaust manifold

• First remove the fuel tank and the ex-

haust tailpipes
• Disconnect from their support the con-
nectors of the lambda probe wiring har-
ness.
• Using a screwdriver, press the tab and
pull the wiring harness downward at
the same time

• Disconnect the connectors of the lamb-

da probe wiring harness
NOTE
REPEAT THIS OPERATION ON THE OPPOSITE SIDE

CHAS - 240
V7 E5 Special-Stone Chassis

• Remove the nuts and the correspond-

ing fixing washers of the exhaust mani-
folds

• Remove the exhaust manifolds at the

same time

Removing the lambda sensor

• First remove the fuel tank

• Disconnect from their support the con-
nectors of the lambda probe wiring har-
ness.
• Using a screwdriver, press the tab and
pull the wiring harness downward at
the same time

• Disconnect the connectors of the lamb-

da probe wiring harness
NOTE
REPEAT THIS OPERATION ON THE OPPOSITE SIDE

CHAS - 241
Chassis V7 E5 Special-Stone

• Unscrew and remove the lambda

probe from the exhaust manifold

Secondary air system

Tightening torques

SECONDARY AIR SYSTEM

Pos. Description Type Quantity Torque Notes
1 Red valve cover fixing SHC screws M5x16 4 3-4 Nm (2.21-2.95 lb ft) -

CHAS - 242
V7 E5 Special-Stone Chassis

Key:
1. Air filter box
2. Secondary air valve
3. Secondary air system pipe
4. Secondary air system inlets on the engine

• Two auxiliary air inlets have been included in the cylinder head which, in combination with
the injection system with oxygen sensor and three-way catalytic converter, ensure compli-
ance with severe new Euro 5 emissions regulations

CHAS - 243
Chassis V7 E5 Special-Stone

• Disconnect the Blow-by pipe from the

reed valve cover

• Undo the screws fastening the reed

valve cover.

• Remove the reed valve cover

• Remove the reed valve.

CHAS - 244
V7 E5 Special-Stone Chassis

• Remove the flame trap.

• A valve controlled by the engine ECU

is installed under the tank, which al-
lows the air from cylinders to flow via
two flexible hoses.

• This valve is connected directly to the

filter box via a flexible hose.

CHAS - 245
Chassis V7 E5 Special-Stone

Evaporative emissions control system

key:
1. Canister
2. SAE 30 R12A-3/16 pipe
3. Breather valve
4. SAE 30 R12A-1/4 pipe
5. SAE 30 R12A-1/4 pipe

• The canister is installed with the intake

inlet above the tank inlet

• Check the correct passage of the pipes on the chassis

CHAS - 246
V7 E5 Special-Stone Chassis

• Check the correct passage of the pipes

on the starter motor

CHAS - 247
INDEX OF TOPICS

BRAKING SYSTEM BRAK SYS

V7 E5 Special-Stone Braking system

ABS

ABS SYSTEM
Pos. Description Type Quantity Torque Notes
1 Control unit bracket fastening to the M6x16 2 10 Nm (7.38 lbf ft) -
frame
2 Screw fastening brake lines fasten- M4 1 3 Nm (2.21 lbf ft) -
ing plates
3 Clamp fastening screw M5 1 6 Nm (4.43 lbf ft) -

BRAK SYS - 249

Braking system V7 E5 Special-Stone

Key:

1. ABS control unit

2. Front ABS sensor
3. Rear ABS sensor
4. Battery
5. Injection loads relay
6. ECU
7. Instrument panel
8. K line (diagnosis)
9. Ignition switch
[Link]
[Link] light switch
[Link] switch left

ABS control unit pin out

1. Ground lead
2. Ground lead
3. /
4. Live supply (+ key)
5. CAN H line
6. CAN L line
7. /
8. ABS Warning light control
9. /
10./
[Link] ABS sensor positive signal
[Link] ABS sensor ground
[Link] ABS sensor ground
[Link] ABS sensor positive signal
[Link] lead
16.K diagnostic line
[Link] unit power

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V7 E5 Special-Stone Braking system

Foreword

Key:

1. ABS control unit

2. ABS control unit front pump pipe
3. ABS control unit front calliper pipe
4. ABS control unit rear calliper pipe
5. ABS control unit rear pump pipe
6. Washer
7. Oil pipe screw
8. Brake pipe support
9. Bushing
[Link] ring
[Link]
[Link]
[Link] unit support bracket
[Link] pipe mounting plate
[Link] fixing plate
[Link]
[Link]
[Link]
[Link]

BRAK SYS - 251

Braking system V7 E5 Special-Stone

[Link]
[Link] guide
[Link]

Operating diagram

ABS functional diagram key

BRAK SYS - 252

V7 E5 Special-Stone Braking system

1. Front system circuit

2. Front brake pump
3. Front brake lever
4. Rear system circuit
5. Rear brake pump
6. Rear brake pedal control
7. ABS control unit
8. Rear brake calliper
9. Front Calliper
[Link] brake circuit intake solenoid valve (normally open)
[Link]
[Link] brake circuit intake solenoid valve (normally open)
[Link] brake exhaust circuit solenoid valve (normally closed)
[Link]/front brake circuit low pressure accumulator
[Link] brake exhaust circuit solenoid valve (normally closed)
[Link] electric motor
[Link] circuit hydraulic pump (ABS)
[Link] brake reservoir
[Link] brake reservoir

ABS OPERATION
General specifications:
The front circuit is the same as the rear one.

• The ABS inlet valve (10 - 12) is normally open and it is closed only when the system inter-
venes to avoid wheel locking.
• The exhaust valve (13 - 15) is normally closed and it is opened only when the system in-
tervenes to avoid wheel locking.
• With the system in stand-by mode, the ABS processor controls the wheel speed instant by
instant to assess any slippage of the wheels.
• When in standby, the system does not intervene at all when the rider brakes; the braking
system is the same as the one without ABS.

ABS Cycle phases (the following operations refer to the front circuit but they are also valid for
the rear):
A - Brake activation: the rider starts braking as he would usually do.
B - Pressure reduction: coincides with the recognition of the dangerous situation (wheel slippage
exceeds the threshold): the system closes the inlet valve (10-12) and opens the exhaust valve (13-15)
temporarily.

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Braking system V7 E5 Special-Stone

At this stage the rider cannot increase the pressure on the callipers (8-9) and the system reduces the
pressure on the callipers partially. The excess fluid temporarily fills the front reservoir (18-19) until the
ABS pump (17) self-activates and delivers the fluid back to the brake pump (2-5).
C - Maintaining pressure: the pressure in the callipers (8-9) remains low until total recovery of speed /
wheel grip.
The system restores the fluid taken from the calliper (8-9) in the section of the system between the
brake pump (2-5) and the ABS inlet valve (10-12).
D - Pressure restoration: by opening the inlet valve (10-12) momentarily, the pressure of the callipers
(8-9) is increased until maximum deceleration is reached. Then, the system gives the control over the
braking back to the rider.
E - If the wheel does not reach complete grip, the system continues operating as before until complete
grip is obtained or until the vehicle stops. An error may be shown in the event that the duration of the
pressure reduction phase exceeds a predetermined time limit.

ABS SYSTEM DESCRIPTION

The ABS system is a device to avoid wheels locking in case of emergency braking, increasing vehicle
braking stability when compared to a traditional braking system.
Sometimes when the brake is operated, the tyre locks with a consequent loss of grip, which makes it
difficult to control the vehicle. A position sensor (3) on the tone wheel (2), forming an integral unit with
the vehicle wheel, "reads" the status of the vehicle wheel spotting any possible lock.
A control unit (1) signals this out and adjusts the pressure in the braking circuit accordingly.
NOTE
WHEN THE ABS STARTS WORKING, A PULSING IS FELT ON THE BRAKE LEVER.

THE WHEEL ANTILOCK BRAKING SYSTEM DOES NOT PREVENT FALLS WHILE ON A BEND.
AN EMERGENCY BRAKING WITH THE VEHICLE INCLINED, HANDLE BAR TURNED, ON UN-
EVEN OR SLIPPERY ROADS, OR WITH POOR GRIP CREATES LACK OF STABILITY DIFFICULT
TO HANDLE. THEREFORE, RIDE CAREFULLY AND SENSIBLY AND ALWAYS BRAKE GRADU-
ALLY. BRAKING WHILE TURNING A CORNER IS SUBJECT TO LAWS OF PHYSICS WHICH NOT
EVEN ABS CAN ELIMINATE.

When the sensors (3) detect a significant speed difference between the rear and the front wheels (for
example, when rearing up on the back wheel), the ABS system could take this as a dangerous situation.

BRAK SYS - 254

V7 E5 Special-Stone Braking system

In this case, there are two possible results:

• The ABS system intervenes by releasing pressure from the calliper until the wheel turns
again at the same speed of the other wheel. It is not possible to brake for an instant.
• if the speed difference lasts long, the system may detect an error and deactivate the ABS
system. As a consequence, the system works like any regular braking system.

Riding with an active ABS system

• When turning the key on, the ABS

warning light turns on and flashes until
reaching 5 km/h (3.11 mph); at this
point it turns off.
CAUTION

THE STEADY LIGHTING OR THE CONTINUOUS FLASHING

OF THE ABS WARNING LIGHT INDICATES THE PRES-
ENCE OF AN ANOMALY AND THE DEACTIVATION OF THE
ABS FUNCTIONALITY.

20 A fuse (ABS Main fuse) (6)

Protects: ABS Control unit.

Guide to diagnosis

PREMISE
Each time the key is ON, at least one current or stored* error of the ABS system is often detected:

• the ABS warning light turns on permanently

The ABS system is deactivated!

The system operates perfectly just as any other braking system without ABS
* The diagnosis requires exceeding the 5 km/h.

Each time the key is ON, if at least one current or stored* error of the ABS system is not detected:

• the ABS warning light flashes

When the 5 km/h (3.11 mph) are exceeded:

- if errors are not detected

BRAK SYS - 255

Braking system V7 E5 Special-Stone

• the ABS warning light turns off

- if at least one malfunction is detected

• the ABS warning light turns on permanently

The ABS system is deactivated!

The system operates perfectly just as any other braking system without ABS.

The detection of malfunctions may require more or less time according to the type of failure.
Error detection logic foresees that for the errors to be diagnosed one or more conditions must persist
within a given time.
If during this given time one of the conditions is missing but then it comes back, the timer is reset and
the system is no longer able to diagnose the error.
The ABS system is still inactive.
Example:
- error code 5D93 requires some minutes before it is diagnosed during the given time:

• the ABS warning light ABS keeps flashing

GUIDE TO ABS FAULT DIAGNOSIS

1. ABS LAMP ON
2. CONNECT PADS
PADS COMMUNICATE? (NO, go to 3; YES, go to 4)

3. PERFORM THESE CHECKS:

• A. PIN 1 Ground connection

• B. +12V at PIN 18
• C. +12V at PIN 4 with key ON

4. ARE THERE ANY ERRORS? YES, go to point 5; NO, go to 6)

5. CHECK THE ERRORS TABLE

6. ABS WARNING LIGHT ACTIVATION
IS IT ACTIVATED?(YES, go to point 7; NO, go to point 8)

7. CONTACT TECHNICAL SERVICE

8. PERFORM THESE CHECKS:

• A. Cable continuity between PIN8 of the ABS control unit connector and the instrument panel
warning light.
• B. Check connectors - refer to the operations described in the chapter

If the above checks are OK, the causes can be:

• C. ABS Control unit malfunction

• D. Instrument panel malfunction

BRAK SYS - 256

V7 E5 Special-Stone Braking system

NOTE: to carry out a check using the diagnostic tool on the wheel speed sensor, refer to the
operations described in chapter ""ELECTRICAL SYSTEM/CHECKS AND CONTROLS/SPEED
SENSOR" chapter.

Use of diagnostics instrument for ABS system

Abs screen pages

ECU INFO screen page

Diagnostic tool - Control unit info screen page

In this screen page are read the general data re-
garding the control unit, for example: type of soft-
ware, mapping, control unit programming data

• Frame number
• SW version (software version)
• Vehicle code
• Vehicle manuf. or encoding
• Vehicle ID PIN 2, 15 or ECU

PARAMETERS screen page

Diagnostic tool - Parameters

This screen page is used to adjust some control
unit parameters

• Front wheel speed

• Rear wheel speed

BRAK SYS - 257

Braking system V7 E5 Special-Stone

Quality test of the sensors

When turning the wheel or acting on the brake, a variation of parameters must be detected.

ACTIVATION screen page

On this screen, you can delete the errors from the

memory of the controller and you can enable some
systems controlled by the control unit.

ACTIVATIONS
Diagnostic tool characteristics Value/example Units of Notes
measure
ment
ABS Warning Light - - During the test the warning light flashes
Front brake bleed - - Useful in the event of sponginess of the lever, de-
spite the bleeding having been performed like in a
traditional brake system
Rear brake bleed - - Useful in the event of sponginess of the lever, de-
spite the bleeding having been performed like in a
traditional brake system

BRAK SYS - 258

V7 E5 Special-Stone Braking system

ERRORS screen page

This display shows potential errors detected in the

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

ERRORS
Diagnostic tool characteristics Notes
Front wheel speed sensor: Electric malfunction 5D90 Electrically defective wiring or sensor
Front wheel speed sensor: The signal changes irregularly Faulty sensor; Signal interference
5D91
Front wheel speed sensor: the signal decreases periodically Possible tone wheel fault due to deformations or dirt; possible
5D92 alterations on the wheel bearing surface; abnormal tone wheel
vibrations
Front wheel speed sensor: Missing signal or speed too low in Faulty sensor; missing sensor or tone wheel; excessive dis-
relation to the rear wheel 5D93 tance between the sensor and the tone wheel; tone wheel with
wrong number of teeth;
Front wheel speed sensor: missing acceleration after pressure Faulty sensor; missing sensor or tone wheel; excessive dis-
reduction 5D94 tance between the sensor and the tone wheel
Front wheel speed sensor: Excessive speed detected 5D95 Faulty sensor; tone wheel with wrong number of teeth; wrong
tyre size
Rear wheel speed sensor: electrical malfunction 5DA0 Electrically defective wiring or sensor
Rear wheel speed sensor: the signal works irregularly 5DA1 Faulty sensor; Signal interference
Rear wheel speed sensor: the signal decreases periodically Possible tone wheel fault due to deformations or dirt; possible
5DA2 alterations on the wheel bearing surface; abnormal tone wheel
vibrations
Rear wheel speed sensor: No signal or speed measured too Faulty sensor; missing sensor or tone wheel; excessive dis-
low in relation to the front wheel 5DA3 tance between the sensor and the tone wheel; tone wheel with
wrong number of teeth;
Rear wheel speed sensor: missing acceleration after pressure Faulty sensor; missing sensor or tone wheel; excessive dis-
reduction 5DA4 tance between the sensor and the tone wheel
Rear wheel speed sensor: Excessive speed detected 5DA5 Faulty sensor; tone wheel with wrong number of teeth; wrong
tyre size
Control unit 5DD3 Possible control unit fault
Recirculation pump 5DF0 Possible control unit fault
Recirculation pump 5DF1 Possible control unit fault
Control unit 5DF2 Possible control unit fault
Low electrical voltage - long period detection 5DF3 Excessively low voltage detected at PIN 18 of ABS ECU for 30
seconds. Possible fault at regulator / battery discharge
Low electrical voltage 5DF4 Insufficient high voltage detected at PIN 18 of ABS ECU. Check
that the PIN 18 of the control unit and the connection of the fuse
are not oxidised, if not ok restore; if ok check the integrity of the
orange/red cable on the ABS control unit side and the red cable
on the battery side
Control unit 5DF5 Possible control unit fault
High electrical voltage 5DF7 Excessively high voltage detected at PIN 18 of ABS ECU. Pos-
sible fault at regulator
Vehicle encoding 5E59 Inconsistency detected between memory coding (INFO ECU/
Vehicle code) and what is measured at wiring harness identi-
fication PIN (INFO ECU screen page, Vehicle identification line
- Pins 2-15 of ABS control unit)
Control unit F01F Possible control unit fault

BRAK SYS - 259

Braking system V7 E5 Special-Stone

Diagnostic tool report diagnostic tool

In the following are described the procedure to be
performed through the diagnostic tool in order to
generate an errors report:

• When started the program, select the

brand.

• Select the vehicle and the component.

• Select Self-diagnosis.

• Go to the page Error codes.

• Select an error and show the Ambient

parameter error(where provided).

BRAK SYS - 260

V7 E5 Special-Stone Braking system

• Repeat the operation by selecting each

error and showing the corresponding
Ambient parameter error (where provi-
ded).

• Go to the page Report and then on

Print and select the virtual PDF printer.

• If there is no PDF printer, there are

several free programs, ask the infor-
mation systems to install it.
• Name the file with a name that contains
the main information of the vehicle and
the analysed component e.g. CN1200-
Chassis0465-Instrument panel.

BRAK SYS - 261

Braking system V7 E5 Special-Stone

Modulator

Before removing the modulator, the braking

system must be completely emptied.
MODULATOR REMOVAL

• Disconnect the connector of the lamb-

da probe and move the wiring harness
from the area in which the operations
will be performed
• Remove the three screws of the pipe
feedthrough and then move it away
from the chassis, to release the pipes
of the front brake

• Remove the left lambda probe from the

exhaust manifold
• Remove the three connector cover fix-
ing screws

• Disconnect the connector from the

modulator

• Remove the screws that fasten the

voltage regulator to the chassis
• Remove the regulator an the horn from
the vehicle

BRAK SYS - 262

V7 E5 Special-Stone Braking system

• Remove the front screws of the modu-

lator support

• Remove the side screw of the modula-

tor support

• Turn the modulator to the left to gain

access to the lower fixing screw
• Remove the fixing screw and detach
the modulator from its support

• Remove the modulator support from

the vehicle, taking it out from the left
side

BRAK SYS - 263

Braking system V7 E5 Special-Stone

• Put a wipe under the modulator

• Remove the brake pipe couplings from
the modulator, making sure to retrieve
all the copper seal washers

• Remove the modulator's pipe guide

• Remove the modulator from the vehi-

cle, taking it out from the right side

BRAK SYS - 264

V7 E5 Special-Stone Braking system

Rear brake calliper

REAR BRAKE CALLIPER

Pos. Description Type Quantity Torque Notes
1 Rear brake calliper fixing screw M8 2 25 Nm (18.44 lbf ft) -
2 Screw fastening the calliper holder M16x1 1 35 Nm (25.81 lb ft) -
plate to the swingarm

Key:

BRAK SYS - 265

Braking system V7 E5 Special-Stone

1. Rear brake calliper

2. Spacer
3. Brake calliper mounting plate
4. Screw fastening the plate to the swingarm
5. Screws fastening the calliper to the plate
6. Bleed + cap
7. Pins + spring kit
8. Brake pads copy

Removal

• Obtain a special container and empty

the system
• Remove the screw fixing the brake
pipe to the clamp

• Remove the two calliper fixing screws

• Remove the calliper

BRAK SYS - 266

V7 E5 Special-Stone Braking system

Front brake calliper

FRONT BRAKE CALLIPER

Pos. Description Type Quantity Torque Notes
1 Screws fastening front brake calliper M10 2 50 Nm (36.88 lb ft) -

Key:

1. Front left brake calliper

BRAK SYS - 267

Braking system V7 E5 Special-Stone

2. Screw
3. Bleed + cap
4. Spring
5. Pins + calliper springs
6. Pair of pads

Removal

• Obtain a special container and empty

the system
• Remove the screw fixing the brake
pipe to the clamp

• Remove the two calliper fixing screws

• Remove the calliper

Rear brake disc

(SPECIAL)

BRAK SYS - 268

V7 E5 Special-Stone Braking system

(STONE)

REAR WHEEL
Pos. Description Type Quantity Torque Notes
1 Rear brake disc fastening screws M8 6 25 Nm (18.44 lbf ft) Loctite 243
2 Rear wheel axle fastener pin + nut M20 1 100 Nm (73.77 lb ft) -
3 ABS sensor fixing screw M6 1 6 Nm (4.43 lbf ft) Loctite 243

BRAK SYS - 269

Braking system V7 E5 Special-Stone

Removal
• Remove the rear wheel
• Remove the six fixing screws (1) of the
tone wheel and the front disc

• Remove the tone wheel (2)

• Remove the brake disc (3)

DURING REFITTING, APPLY LOCTITE 243 ON THE

THREAD OF THE BRAKE DISC SCREWS (1).
CAUTION
DURING 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.

BRAK SYS - 270

V7 E5 Special-Stone Braking 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

(SPECIAL)

(STONE)

BRAK SYS - 271

Braking system V7 E5 Special-Stone

FRONT WHEEL
Pos. Description Type Quantity Torque Notes
1 Wheel axle M18 1 80 Nm (59.00 lb ft) -
2 Front brake disc fixing screws M8 6 25 Nm (18.44 lbf ft) Loctite 243
3 ABS-sensor fixing stud bolt M5 1 6 Nm (4.43 lbf ft) Pre-permeated
4 Cable grommet nut M6 1 6 Nm (4.43 lbf ft) -

Removal

• Remove the rear wheel

• Remove the six fixing screws (1) of the
tone wheel and the front disc

BRAK SYS - 272

V7 E5 Special-Stone Braking system

• Remove the tone wheel (2)

• Remove the brake disc (3)

DURING REFITTING, APPLY LOCTITE 243 ON THE

THREAD OF THE BRAKE DISC SCREWS (1).
CAUTION
DURING 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 FRONT BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE
SPECIFICATIONS OF THE SYSTEM.
• 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

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Braking system V7 E5 Special-Stone

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 Seeger locking the retain-

ing pins of the brake pads

• Remove the brake pad retaining pins

• Collect the protection plate.

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• Remove the brake pads

Rear brake pads

Removal

• Remove the rear brake calliper

• Remove the screws locking the brake

pads

• Remove the brake pads

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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
IN VIEW OF THE DANGER THIS POSES FOR VEHICLE AND RIDER, THE HYDRAULIC CIRCUIT
MUST BE BLED AFTER REFITTING THE BRAKES AND RESTORING THE BRAKING SYSTEM TO
ITS NORMAL OPERATING CONDITIONS.
NOTE
THE VEHICLE MUST BE ON LEVEL GROUND TO BE BLED. WHILE BLEEDING THE HYDRAULIC
SYSTEM, FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID. CHECK
THAT, DURING THE OPERATION, THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR.
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 fluid 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.

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• 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
IN VIEW OF THE DANGER THIS POSES FOR VEHICLE AND RIDER, THE HYDRAULIC CIRCUIT
MUST BE BLED AFTER REFITTING THE BRAKES AND RESTORING THE BRAKING SYSTEM TO
ITS NORMAL OPERATING CONDITIONS.
NOTE
THE VEHICLE MUST BE ON LEVEL GROUND TO BE BLED. WHILE BLEEDING THE HYDRAULIC
SYSTEM, FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID. CHECK
THAT, DURING THE OPERATION, THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR.
• 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 fluid 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.

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• Refit and lock the rear brake oil reservoir cap.

• Refit the rubber protection cover.

Front brake pump

FRONT BRAKE MASTER CYLINDER

Pos. Description Type Quantity Torque Notes
1 Front brake master cylinder U-bolt fixing M6 2 10 Nm (7.38 lbf ft) -
screws
2 Brake light switch fastening screws M4 1 3 Nm (2.21 lbf ft) -

Removal

• Remove the rear-view mirror

• Drain off the front brake system
• Disconnect the brake switch connec-
tors

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• Remove the two brake pump fixing

screws

• Remove the brake pump

CAUTION
DURING REFITTING FILL UP THE BRAKE SYSTEM WITH
THE RELATIVE BLEEDING PROCEDURE TO AVOID AIR
BUBBLES IN THE SYSTEM

Rear brake pump

REAR BRAKE PUMP

Pos. Description Type Quantity Torque Notes
1 Brake master cylinder reservoir fixing M6 2 10 Nm (7.38 lbf ft) -
screws
2 Brake light switch fastening - 1 5 Nm (3.69 lb ft) Loctite 243

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Pos. Description Type Quantity Torque Notes

3 Rear brake lever peg fastening - 1 20 Nm (14.75 lbf ft) Loctite 243
4 Rear brake lever fixing pin - 1 20 Nm (14.75 lbf ft) -
5 Fork fixing nut M6 1 10 Nm (7.38 lbf ft) -

Rimozione

(SPECIAL/STONE)

• Use an appropriate container to recov-

er the oil inside the brake system.
• Remove the brake pipe by acting on
the fitting and empty the system

• Remove the two brake pump rear fixing

screws at the support plate

• Move the O-Ring from the retainer

plate and remove it

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• Remove the brake pump

Brake system lines

Removal

• Drain the braking system

• Remove the saddle
• Remove the fuel tank
• Remove the silencers
CAUTION
WHILE IT IS NOT MANDATORY TO REMOVE THE SILENCERS, WE RECOMMEND DOING SO IN
ORDER TO AVOID CAUSING ANY SUPERFICIAL DAMAGE TO THEM.
REMOVING THE FRONT BRAKE PIPE (BETWEEN THE BRAKE FLUID TANK AND THE ABS
CONTROL UNIT)

• Remove the right lambda probe

• Remove the ABS modulator support according to the indication in the Modulator section

• Remove the brake pipe connector from

the ABS modulator
• Retrieve the screw and the associated
seal washers

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• Remove the brake pipe coupling from

the front brake master cylinder
• Retrieve the screw and the associated
seal washers

• Remove the rubber clamps fastening

the switch cables to the brake pipe

• Slide the brake pipe out of the vehicle,

as indicated in figure, sliding it through
the vehicle's cable ties

REMOVING THE FRONT BRAKE PIPE (BETWEEN THE BRAKE CALLIPERS AND THE ABS CON-
TROL UNIT)

• Remove the right lambda probe

• Remove the ABS modulator support according to the indication in the Modulator section

• Remove the brake pipe connector from

the ABS modulator
• Retrieve the screw and the associated
seal washers

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• Remove the brake pipe coupling from

the front brake calliper
• Retrieve the screw and the associated
seal washers

• Remove the cable ties fastening the

ABS sensor cable to the brake pipe

• Remove the screw fixing the pipe feed-

through to the lower plate of the forks

• Remove the vehicle's brake pipe

REMOVING THE REAR BRAKE PIPE (BETWEEN THE BRAKE FLUID TANK AND THE ABS CON-
TROL UNIT)

• Remove the right lambda probe

• Remove the ABS modulator support according to the indication in the Modulator section

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• Remove the clamp fastening the brake

pipes to the chassis

• Open the brae pipe fastener tab

• Remove the brake pipe connector from

the ABS modulator
• Retrieve the screw and the associated
seal washers

• Remove the plate (1) from the brake

pipe support bracket
• Release the pipes from the bracket

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• Remove the brake pipe coupling from

the rear brake master cylinder
• Retrieve the screw and the associated
seal washers

• Remove the vehicle's brake pipe

REMOVING THE REAR BRAKE PIPE (BETWEEN THE BRAKE CALLIPERS AND THE ABS CON-
TROL UNIT)

• Remove the right lambda probe

• Remove the ABS modulator support according to the indication in the Modulator section

• Remove the clamp fastening the brake

pipes to the chassis

• Open the brae pipe fastener tab

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• Remove the plate (1) from the brake

pipe support bracket
• Release the pipes from the bracket

• Remove the brake pipe connector from

the ABS modulator
• Retrieve the screw and the associated
seal washers

• Remove the cable ties fastening the

ABS sensor cable to the rear brake
pipe

• Remove the cable tie behind the rear

brake pump
• Remove the cable tie located under the
swingarm, next to the gearbox cardan
shaft output

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• Remove the screw fixing the pipe feed-

through to the swingarm

• Remove the brake pipe coupling from

the rear brake calliper
• Retrieve the screw and the associated
seal washers

• Remove the vehicle's brake pipe

BRAK SYS - 287

INDEX OF TOPICS

BODYWORK BODYW
V7 E5 Special-Stone Bodywork

REAR LIGHT ASSEMBLY

Pos. Description Type Quantity Torque Notes
1 Taillight to internal support fixing screws SWP 3 2 2 Nm (1.48 lb ft) -
2 Screws fastening the internal support to the SWP 3 3 2 Nm (1.48 lb ft) -
lower cover
3 Upper cover fixing screws SWP 3 3 2 Nm (1.48 lb ft) -
4 Screws fastening the taillight to the mudguard SWP 3 3 5 Nm (3.69 lb ft) -
5 Direction indicator fastening screws M6 2 5 Nm (3.69 lb ft) -
6 Licence plate light fastening screws M4 2 3 Nm (2.21 lbf ft) -
7 Screw fixing the reflector to the support M5 1 4 Nm (2.95 lb ft) -
8 Screws fastening reflector support to the plate M5 2 4 Nm (2.95 lb ft) -
holder

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REAR MUDGUARD
Pos. Description Type Quantity Torque Notes
1 Rear mudguard fixing screws M8 2 20 Nm (14.75 lbf ft)
2 Front and centre fastening screw rear mud- M6 3 8 Nm (5.9 lb ft)
guard
3 Rear splash guard fastening screws M6 2 10 Nm (7.38 lbf ft)

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LOCK KIT
Pos. Description Type Quantity Torque Notes
1 (Shear head) screw fixing ignition M8 1 At the point of failure Loctite 243
lock
2 Ignition lock fixing screw M8 1 25 Nm (18.44 lbf ft) Pre-permeated
3 Saddle release block fixing screws M6 2 10 Nm (7.38 lbf ft) -

CENTRAL BODYWORK
Pos. Description Type Quantity Torque Notes
1 Starter motor cover fastening screws M5 2 4 Nm (2.95 lb ft) -
2 Throttle body cover fastening screws M5 4 3 Nm (2.21 lbf ft) -
3 Side panel fastening screws M5 2 4 Nm (2.95 lb ft) -

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FILTER BOX
Pos. Description Type Quantity Torque Notes
1 Filter box fastening screws SWP M5 9 3 Nm (2.21 lbf ft) -
2 Air filter cover fastening screws SWP M5 4 3 Nm (2.21 lbf ft) -
3 Filter casing/frame fastening screw SWP M5 2 3 Nm (2.21 lbf ft) -

FUEL TANK
Pos. Description Type Quantity Torque Notes
1 Screws fastening fuel pump to fuel tank M5 6 5 Nm (3.69 lb ft) Pre-permeated

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Pos. Description Type Quantity Torque Notes

2 Rear tank fastening screw M8 1 25 Nm (18.44 lbf ft) -

FRONT MUDGUARD
Pos. Description Type Quantity Torque Notes
1 Screws fastening the stabiliser plate to the fork M8 4 15 Nm (11.06 lbf ft)
2 Screw fastening the mudguard to the stabiliser M6 4 10 Nm (7.38 lbf ft)
plate

Headlight assy.

(SPECIAL)

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HEADLIGHT UNIT
Pos. Description Type Quantity Torque Notes
1 Headlamp fastening screws M8x45 2 15 Nm (11.06 lbf ft) -
2 Front turn indicators SHC fastening screws M6x25 2 10 Nm (7.38 lbf ft) -
3 SHC screws fastening the headlight support M6x25 2 10 Nm (7.38 lbf ft) -
strips

(STONE)

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HEADLIGHT UNIT
Pos. Description Type Quantity Torque Notes
1 Headlamp fastening screws M8 2 15 Nm (11.10 lb ft) -
2 Front turn indicators fastening screws M6 2 5 Nm (3.69 lb ft) -
3 Screws fastening the headlight support strips M6 2 10 Nm (7.38 lbf ft) -

(HALOGEN VERSION)

• Remove the two screws fixing the

headlamp to the supports

• Move the headlamp from the supports

and remove the spacers

• Disconnect the connector from the

headlamp and remove it

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BULB REPLACEMENT

• To replace the bulbs, remove the com-

plete parabole from the headlight body
by undoing the screw (1)

LOW BEAM / HIGH BEAM LIGHT BULB

• Pull out the electrical connection to the bulb (2), and disconnect it from the bulb.
• Move hood (3) manually.
• Release the two ends of the retaining spring (4) located on the bulb holder.
• Pull the bulb (5) out of its fitting.
NOTE
INSERT THE BULB INTO THE BULB HOLDER, MAKING SURE THE REFERENCE FITTINGS
MATCH.

TAIL LIGHT BULB

• Pull out the daylight running light bulb holder (6) from its seat.
• Remove the bulb (7) and replace it with another of the same type.
• Check the proper insertion of the bulb in the bulb holder.

(LED VERSION)

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V7 E5 Special-Stone Bodywork

• Unscrew the two headlamps fixing

screws

• Support the headlamp and then re-

move the screws (1) and the bushings
(2)

• Release the safety (3) by sliding it in

opposite direction to the headlamp
• Press the tab (4) and simultaneously
disconnect the connector from the
headlamp

• Remove the headlamp (5) from the ve-

hicle

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FRONT HEADLIGHT SUPPORT REMOVAL

• Remove the front light assembly

• Remove the front turn indicators
• Unscrew and remove the screws (1)
• Remove the upper U-bolt
• Temporarily remove the handlebar
from the lower U-bolts

• Unscrew and remove the ring nut (2)

• Loosen the screws (3) from both sides

of the vehicle
• Remove the upper steering plate

• Undo and remove the screw (4)

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• Remove the headlamp supports (5)

from both sides of the vehicle

Turn indicators

REMOVING FRONT TURN INDICATORS

The following procedure is described for one turn
indicator, but it is valid for both turn indicators

• Remove the front light cluster

• Unscrew and remove the two screws
(1)

• Remove the cover (2)

• Remove the clamp (3)

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• Disconnect the connector (4)

• Undo and remove the screw (5)

• Remove the front turn indicator (6)

• Undo and remove the screw (5)

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• Remove the front turn indicator (6)

REAR TURN INDICATORS REMOVAL

The following procedure is described for one turn
indicator, but it is valid for both turn indicators

• Remove the rear light cluster

• Unscrew and remove the three fasten-
ing screws (1) from the cover

• Remove the cover (2)

• Disconnect the connector (3)

• Undo and remove the screw (4)

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Bodywork V7 E5 Special-Stone

• Remove the turn indicator (5)

Disassembling the lock

• Remove the LH side fairing

• Remove the saddle opening cable (1)
from its housing

• Remove the fork spring (2)

• Remove the cable support plate (3)

BODYW - 302
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• Remove the ignition switch assembly

(4)

Taillight assy.

REAR LIGHT ASSEMBLY

Pos. Description Type Quantity Torque Notes
1 Taillight to internal support fixing screws SWP 3 2 2 Nm (1.48 lb ft) -
2 Screws fastening the internal support to the SWP 3 3 2 Nm (1.48 lb ft) -
lower cover
3 Upper cover fixing screws SWP 3 3 2 Nm (1.48 lb ft) -
4 Screws fastening the taillight to the mudguard SWP 3 3 5 Nm (3.69 lb ft) -
5 Direction indicator fastening screws M6 2 5 Nm (3.69 lb ft) -
6 Licence plate light fastening screws M4 2 3 Nm (2.21 lbf ft) -
7 Screw fixing the reflector to the support M5 1 4 Nm (2.95 lb ft) -
8 Screws fastening reflector support to the plate M5 2 4 Nm (2.95 lb ft) -
holder

LICENCE PLATE LIGHT REMOVAL

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• Remove the rear mudguard from the

vehicle
• Remove the screws (1) that fasten the
licence plate holder to the rear mud-
guard and retrieve the centring bush-
ings

• Remove the lower reinforcement (2)

from the mudguard

• Disconnect the licence plate light wir-

ing harness connector
• Remove the plate holder from the rear
mudguard

• Remove the two screws (3) fixing the

licence plate light to the plate holder

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V7 E5 Special-Stone Bodywork

• Remove the licence plate light from the

plate holder

TAILLIGHT REMOVAL

• Remove the plate holder from the rear

mudguard
• Remove the three nuts (3) that fasten
the taillight to the mudguard

• Loosen the screws (4) that fasten the

wiring harness to be able to displace
the rear mudguard

• Remove the taillight from the mud-

guard

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Bodywork V7 E5 Special-Stone

• Remove the three fixing screws of the

taillight half cases
• Remove the upper half case of the tail-
light

• Disconnect the taillight connector (5)

• Remove the fixing screws (6);

• Remove the fixing screw (7) that was

under the taillight connector

• Remove the taillight together with its

support from the lower half case

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• Remove the fixing screws (8) and de-

tach the taillight from its support

Footrest

(SPECIAL/STONE)

REMOVAL OF THE RIGHT-HAND RIDER

FOOTREST SUPPORT

• Remove the gasket (1)

• Unhook and remove the clip (2)

• Holding the nut in place as illustrated in

the figure, unscrew and remove the
two rear brake master cylinder fasten-
ing screws (3)

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Bodywork V7 E5 Special-Stone

• Undo and remove the two fastening

screws (4)

• Remove the microswitch (5) turning

the footrest support in order not to
damage the microswitch cabling
• Remove the right-hand rider footrest
support (6)

REMOVAL OF THE REAR BRAKE LEVER

• Remove the right-hand rider footrest

support
• Remove the lever return spring (1)
CAUTION
REMOVE THE BRAKE LEVER RETURN SPRING FROM
THE FOOTREST SUPPORT, TAKING CARE NOT TO
WEAKEN IT.

• Undo and remove the screw (2)

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V7 E5 Special-Stone Bodywork

• Retrieve the O-ring (3)

• Remove the rear brake lever (4)

• Retrieve the O-ring (5)

REMOVAL OF THE RIGHT-HAND RIDER

FOOTREST

• Remove the snap ring(1)

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Bodywork V7 E5 Special-Stone

• Remove the pin (2)

• Remove the right-hand rider footrest
(3)
• Retrieve the spring (4)

• Remove the clip (1)

• Remove the gear shift lever tie-rod (2)

from the ball joint

• Undo and remove the two fastening

screws (3)

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V7 E5 Special-Stone Bodywork

• Remove the left-hand rider footrest

support (4)

REMOVAL OF THE GEAR SHIFT LEVER

• Remove the right-hand rider footrest

• Holding the nut in place as illustrated in
the figure, undo and remove the fas-
tening screw (1)

• Remove the gear shift lever (2)

• Retrieve the bushing (3), the two O-

rings (4), the washer (5) and the nut (6)

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REMOVAL OF THE LEFT-HAND RIDER FOOT-

REST

• Remove the snap ring(1)

• Remove the pin (2)

• Remove the left-hand rider footrest (3)
• Retrieve the spring (4)

REMOVAL OF THE PASSENGER FOOTRESTS

SUPPORT

• Undo and remove the two fastening

screws (1)

• Holding the nut in place as illustrated in

the figure, undo and remove the screw
(2)
• Retrieve the bushing (3)

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V7 E5 Special-Stone Bodywork

• Remove the right-hand passenger

footrest support (4)
• Repeat the entire operation to remove
the left-hand passenger footrest sup-
port

REMOVAL OF THE PASSENGER FOOTREST

• Remove the snap ring(1)

• Remove the pin (2)

• Remove the right-hand passenger
footrest (3)

• Retrieve the two plates (3), the ball (4)

and the spring (5)
• Repeat the entire operation to remove
the left-hand passenger footrest

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Bodywork V7 E5 Special-Stone

Side body panels

CENTRAL BODYWORK
Pos. Description Type Quantity Torque Notes
1 Starter motor cover fastening screws M5 2 4 Nm (2.95 lb ft) -
2 Throttle body cover fastening screws M5 4 3 Nm (2.21 lbf ft) -
3 Side panel fastening screws M5 2 4 Nm (2.95 lb ft) -

• Remove the saddle

• Remove the side fairing fixing screw

• Lift the rear part of the side fairing to

detach it from the coupling to the chas-
sis

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V7 E5 Special-Stone Bodywork

• Slide the side fairing forward

• Disconnect the cable from the latch

and then remove the side fairing from
the vehicle
NOTE
The procedure described refers to the left side fairing but it is
valid for both, except for the latch cable that doesn't exist on
the right side.

Air box

FILTER BOX
Pos. Description Type Quantity Torque Notes
1 Filter box fastening screws SWP M5 9 3 Nm (2.21 lbf ft) -
2 Air filter cover fastening screws SWP M5 4 3 Nm (2.21 lbf ft) -
3 Filter casing/frame fastening screw SWP M5 2 3 Nm (2.21 lbf ft) -

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• Remove the saddle, the side panels

and the battery complete with the rub-
ber support
• Slide from the support present in the
filter casing connector (1) and the ABS
fuses (2)

• Remove the four fastening screws (3)

of the air filter cover

• Remove the air filter cover (4) and the

filter (5)

• Remove the two screws securing the

fuse box support and move it to have
greater freedom of movement for sub-
sequent operations

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V7 E5 Special-Stone Bodywork

• Remove the two screws that fasten the

air filter case to the chassis

• Remove the clamp present in the col-

lector that blocks the filter case to the
throttle body

• Remove the two bottom fastening nuts

of the splash guard

• Operating on the left side of the motorcycle, remove the blow-by pipe (6) from the filter case,
while the right side, remove the secondary air pipe (7)

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• Remove the four screws securing the

filter case support bracket and remove
it by slightly raising the box itself

• Pull the filter case from the right side of

the motorcycle

• Remove the collector from the filter

case

• Remove the locking screws from the

filter case

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V7 E5 Special-Stone Bodywork

• Remove the cover (8) and the blow-by

filter (9)

• Check and replace the two seals

present in the cover

Rear mudguard

REAR MUDGUARD
Pos. Description Type Quantity Torque Notes
1 Rear mudguard fixing screws M8 2 20 Nm (14.75 lbf ft)
2 Front and centre fastening screw rear mud- M6 3 8 Nm (5.9 lb ft)
guard

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Bodywork V7 E5 Special-Stone

Pos. Description Type Quantity Torque Notes

3 Rear splash guard fastening screws M6 2 10 Nm (7.38 lbf ft)

• Remove the saddle

• Unscrew and remove the two screws
(1)

• Unscrew and remove the two fixing

screws (2) from both sides of the vehi-
cle
• Retrieve the two washers (3)

• Undo and remove the screw (4)

• Disconnect the connector (5)

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V7 E5 Special-Stone Bodywork

• Remove the saddle opening cable

from the points indicated in figure

• Remove the rear mudguard (6) com-

plete with the rear light cluster

• Remove the two bushings (7)

• Unscrew and remove the three screws

(8)

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• Remove the strengthener (9)

• Remove the rear light cluster

Splash guard

REAR MUDGUARD
Pos. Description Type Quantity Torque Notes
1 Rear mudguard fixing screws M8 2 20 Nm (14.75 lbf ft)
2 Front and centre fastening screw rear mud- M6 3 8 Nm (5.9 lb ft)
guard
3 Rear splash guard fastening screws M6 2 10 Nm (7.38 lbf ft)

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• Remove the rear mudguard

• Remove the two lower nuts

• Remove the two upper screws com-

plete with self-locking nuts

• Remove the splash guard

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Fuel tank

FUEL TANK
Pos. Description Type Quantity Torque Notes
1 Screws fastening fuel pump to fuel tank M5 6 5 Nm (3.69 lb ft) Pre-permeated
2 Rear tank fastening screw M8 1 25 Nm (18.44 lbf ft) -

• Remove the saddle

• Unscrew the tank fixing screw and re-
trieve the washer

• Move the tank toward the back of the

vehicle and lift it from the chassis

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• Remove the metal clamp

• Remove the breather pipe from the
tank coupling

• Disconnect the fuel pipe coupling from

the pump

• Disconnect the fuel pump wiring har-

ness connector

• Remove the fuel tank from the vehicle

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Front mudguard

FRONT MUDGUARD
Pos. Description Type Quantity Torque Notes
1 Screws fastening the stabiliser plate to the fork M8 4 15 Nm (11.06 lb ft) Loctite 243
2 Screw fastening the mudguard to the stabiliser M6 4 10 Nm (7.38 lb ft) Loctite 243
plate

• Remove the four front mudguard sup-

port fixing screws at the fork sleeves

• Remove the mudguard complete

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V7 E5 Special-Stone Bodywork

• Remove the four screws fixing the

mudguard to the mudguard support

• Remove the mudguard support from

the mudguard

BODYW - 327
A
ABS: 249, 257
Air filter: 58, 61, 62, 64

B
Battery: 118, 124
Brake: 265, 267, 268, 271, 274, 275, 278, 279, 281
Brake calliper: 265, 267
Brake disc: 268, 271
Brake pads: 274, 275
Brake pump: 278, 279
Bulbs:

C
CAN line: 164
Clutch: 145
Coil: 141
Connectors: 152
Cylinder:

D
Diagnostics: 257

E
ECU: 152, 257
Electrical system: 7, 19, 75, 78
Engine oil: 55
Engine temperature sensor: 131
Exhaust: 236, 240
Exhaust manifold: 240

F
Filter box:
Fork: 191, 193, 195, 197
Front wheel: 207
Fuel: 140, 324
Fuel pump: 140
Fuses: 123

G
Gearbox oil: 57

H
Handlebar: 190
Headlight: 293

I
Identification: 17
M
Maintenance: 15, 51, 118
Mudguard: 319, 326

O
Oil filter: 57

R
Rear light:
Rear wheel: 209
Recommended products: 53
Run/Stop switch: 150

S
SAS valve actuator: 149
Scheduled maintenance: 51
Secondary air system: 242
Shock absorbers: 204
Side stand: 147
Side stand sensor: 147
Spark plugs:
Speed sensor: 125
Stand: 147
Start-up: 121

T
Tank: 324
Throttle body: 59
Transmission: 19, 53
Turn indicators: 299
Tyres: 21

U
Use: 257

W
Wiring diagram: 111