MV Agusta Brutale Oro-S Workshop Manual
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MV Agusta Brutale Oro-S Workshop Manual

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Motorcycle Workshop - Manual
MV AGUSTA BRUTALE ORO - S
MOTORE
MOTOTELAIO

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Summary of Contents for MV Agusta Brutale Oro-S

  • Page 1 Motorcycle Workshop - Manual MV AGUSTA BRUTALE ORO - S MOTORE MOTOTELAIO...
  • Page 2 Everything that we do has repercussions on the entire planet and its resources. MV Agusta, wanting to protect the interest of the people, would like to make the client and the technicians of the technical assistance centres aware and to adopt modalities of use of the motorcycle and the disposure of its parts in full respect of the norms in force in terms of environmental pollution, disposal and the recycling of waste.

  • Page 3: Table Of Contents

    Freni General Index GENERAL DESCRIPTION ..................Rev. 0 MAINTENANCE ......................Rev. 1 BODYWORK ......................Rev. 0 AIR INTAKE INJECTION SYSTEM ................Rev. 0 ELECTRICAL SYSTEM .................... Rev. 0 SUSPENSION AND WHEELS .................. Rev. 1 FRAME ........................Rev. 0 BRAKES ........................Rev.

  • Page 5: General Description

    General description SECTION Revision 0 - 1 -...
  • Page 6 General description SUMMARY HOW TO CONSULT THIS MANUAL ......................PAGE 3 PURPOSE OF THE MANUAL ........................PAGE 3 GLOSSARY AND SYMBOLS ........................PAGE 4 RIGHT HAND AND LEFT HAND STANDARD ..................PAGE 5 SAFETY ..............................PAGE 6 WARNING ..............................PAGE 8 INDEX................................PAGE 8 OPERATIVE TECHNICAL SPECIFICATIONS ...................PAGE 9 - 2 -...

  • Page 7: How To Consult This Manual

    All information, instructions and technical data included in this manual are based upon information on the product updated at the moment of going to print. MV Agusta S.p.A. reserves the right to carry out changes at any moment without prior notice and without incurring any obligation.

  • Page 8: Glossary And Symbols

    General description GLOSSARY AND SYMBOLS This signifies that the lack of ATTENTION or the incomplete observan- Use the recommended suspension fluid. ce of this advice can be gra- vely dangerous for your safety and for the safety of other persons. This signifies that the lack of Use the recommended coolant.

  • Page 9: Right Hand And Left Hand Standard

    General description RIGHT HAND AND LEFT HAND STANDARD In order to specify the right/left convention used within the chapters of this manual, see the following motorcycle and engine scheme where all sides which refer to are reported. Cylinder 3 Cylinder 2 Cilindro 2 Cilindro 3 Cylinder 4...

  • Page 10: Safety

    • Used oil contains dangerous substances and poisonous for the environment. To substitute oil, it is recommended to go to an authorised MV Agusta dealer who is equipped to deal with the collection of used oil in respect of the norms in force.
  • Page 11 • The battery contains dangerous substances that are poisonous for the environment. It is advisable to substitute it at an MV Agusta dealer that is equipped to dispose of this product in respect of the norms in force. • Do not dispose of used batteries in the environment.

  • Page 12: Warning

    • Loosening and tightening nuts or screws, always start from the bigger ones or the centre. Always comply with the torque wrench settings. • Utilise only MV Agusta spare parts. INDEX GENERAL INDEX SUMMARY OF EACH CHAPTER...

  • Page 13: Operative Technical Specifications

    General description OPERATIVE TECHNICAL SPECIFICATIONS MOTORCYCLE IDENTIFICATION Frame registration number Engine registration number Homologation date "Limited series" number The registration number of the motorcycle is stamped on the right side of the steering head. The engine part number is stamped on the top half casing near the fork. 4) "Limited series"...
  • Page 14 General description - 10 -...

  • Page 15: Maintenance

    Maintenance SECTION Revision 0 - 1 -...
  • Page 16 Maintenance SUMMARY TECHNICAL INFORMATION........................PAGE 3 TECHNICAL DATA ..........................PAGE 3 COMPONENTS IN CARBON FIBRE (F4 BRUTALE ORO) ..............PAGE 6 MAGNESIUM COMPONENTS (F4 BRUTALE ORO) ................PAGE 7 PERIODICAL MAINTENANCE SCHEDULE ....................PAGE 9 MAINTENANCE AND TUNING OPERATIONS ..................PAGE 11 ENGINE OIL AND OIL FILTER.........................PAGE 11 ENGINE COOLANT ..........................PAGE 19 ELECTRIC COOLING FAN........................PAGE 21 VALVE MECHANISM ADJUSTMENT ......................PAGE 22...

  • Page 17: Technical Information

    Maintenance TECHNICAL INFORMATION 2020 1410 TECHNICAL DATA Description BRUTALE ORO BRUTALE S CHARACTERISTICS Wheelbase (mm) (*) 1410 1410 Total length (mm) (*) 2020 2020 Maximum width (mm) Seat height (mm) (*) Ground clearance (mm) (*) Trail (mm) (*) 101.5 101.5 Dry weight (kg) Fuel tank capacity (litres) (**) Fuel reserve (litres) (**)
  • Page 18 Maintenance TECHNICAL DATA Description BRUTALE ORO BRUTALE S TIMING Type D.O.H.C. radial valves LUBRICATION Type Wet sump IGNITION – FUEL FEED SYSTEM Type Weber-Marelli ignition/injection 1.6 M integrated system Inductive charge electronic ignition, Multipoint electronic injection Spark plugs (alternatively) NGK CR9 EB Champion G59c NGK CR9 EB Champion G59c...
  • Page 19 Maintenance TECHNICAL DATA Description BRUTALE ORO BRUTALE S ELECTRICAL SYSTEM Voltage Front dipped beam light bulb 12V 55W 12V 55W Front main beam light bulb 12V 60W 12V 60W Front sidelight bulb 12V 5W 12V 5W Rear light bulb 12V 5W 12V 5W Rear stop light bulb 12V 21W...

  • Page 20: Components In Carbon Fibre (F4 Brutale Oro)

    Maintenance COMPONENTS IN CARBON FIBRE (F4 BRUTALE ORO) - Right air filter compartment side panel - Ignition switch cover - Left air filter compartment side panel - Tail unit - Right tank side panel 10 - Front mudguard - Left tank side panel 11 - Top chain protection - Right cylinder cover 12 - Lower chain protection...

  • Page 21: Magnesium Components (F4 Brutale Oro)

    Maintenance MAGNESIUM COMPONENTS (F4 BRUTALE ORO) - Steering base - Frame side plate - Front wheel rim - Rear wheel rim - Mono-arm fork - 7 -...
  • Page 22 Maintenance - 8 -...

  • Page 23: Periodical Maintenance Schedule

    Everything that we do has repercussions on the whole planet and on its resources. MV Agusta, to protect the interests of the everyone, ask clients and technical assistance operators to use the motorcycle and dispose of its used parts with respect to the norms in force in terms of environmental pollution, disposal and recycling of refuse.
  • Page 24 Manutenzione Maintenance Programmed maintenance schedule 1000 6000 12000 18000 24000 30000 36000 Frequenza Km (mi) Km (mi) covered (600) (3800) (7500) (11200) (14900) (18600) (22400) Pre- Tagliando Service delivery Description Operation Transmission and flexible controls Check / Adjust Check / Adjust Transmission chain Lubricate Substitution...

  • Page 25: Maintenance And Tuning Operations

    MOTUL CHAIN LUBE PLUS – * : To find the recommended product, MV Agusta suggests going directly to the authorised MV Agusta dealers. AGIP Racing 4T 10W/60 has been manufactured for the F4 engine. If the described oil is not available, MV...
  • Page 26 Maintenance Remove the oil filler plug (1) on the right side of the motorcycle so that it facilitates the discharge of the used oil. Wait until the lubrication system is completely empty of used engine oil. Substitution of the oil filter In order to proceed to replace the oil filter you should remove the exhaust manifolds of the cylinders 3 and 4.
  • Page 27 Maintenance Slightly move the coolers towards the front area of the motorcycle, then unscrew the nut on the fixing flange of 20÷22 N•m the exhaust manifilds of the cylinder group. During this operation pay attention to the exhaust pipes in order to avoid from scor- ching.
  • Page 28 Maintenance Loosen the safety clamp and remove it. Unscrew the oil filter by an appropriate wrench. In the event of a filter branded TOYO ROKI use the wrench for oil filter: TOYO ROKI FACOM D. 139 tool Part code 8000A4317 In the event of a filter branded Champion use the wren- ch for oil filter: Champion...
  • Page 29 - Toyo Roki oil filter kit: Part code 8000A3702 - Champion oil filter kit: Part code 8000A1428 Only use original components of MV Agusta. If you use an oil filter Toyo Roki (Part code 8000A3702), you should the following preliminary ope- ration.
  • Page 30 Maintenance Insert the filter in its seat. Turn the filter manually until the gasket is into slight contact with the machined surface. Tighten the filter using the appropriate tool and a tor- que wrench. - TOYO ROKI oil filter: FACOM D. 139 tool Part code 8000A4317 Oil filter torque wrench: 24 N·m...
  • Page 31 Maintenance Place the clamp lock at a range of 2 mm from the screwhead on the supporting plate of oil cooler pipes. Turn the clamp screw up to bring in contact with the fil- ter without tightening. Mark the screw position drawing a line by a felt-tip both on the screw and on the clamp.
  • Page 32 Maintenance On the oil discharge plug there is a magnet to attract any metal residues that could form in the engine during rotation. Before proceeding with the reassembly of the plug, check that the cleaning has been done thoroughly and also the condition of the gasket seal.

  • Page 33: Engine Coolant

    Maintenance ENGINE COOLANT Check/top-up level At the pre-delivery, at the first 1000 kilome- tres and then every 6000 kilometres Keeping the motorcycle in a vertical position, check that the level of engine coolant is between the «MIN» mark found on the expansion tank (1) and the lower part of the frame tube, that you can see from the ope- ning on the frame protection panel on the left side of the motorcycle.
  • Page 34 Maintenance Engine coolant substitution Substitution Every two years Before proceeding the emptying of the system, Perform the following operations in advance: • Remove the ignition switch cover (see “Engine coolant level check”); • Place a container under the engine to collect the used coolant;...

  • Page 35: Electric Cooling Fan

    Maintenance Complete the assembly of the motorcycle. ELECTRIC COOLING FAN Check on pre-delivery and at the first 1000 kilometres and then every 6000 kilome- tres To carry out the check on the functioning of the electric cooling fan, switch on the engine and heat it up. The electric fan should come into operation when the instrument panel shows a system temperature of about 100 °C.

  • Page 36: Valve Mechanism Adjustment

    Maintenance VALVE MECHANISM ADJUSTMENT Check and adjust at 1000 kilometres and every 12000 kilometres Remove in order the following components to carry out the measuring of the play between the camshaft and the valve cups: • Passenger seat • Rider seat •...
  • Page 37 Maintenance Ensure that all the surfaces of the frame are protected by the application of the adhesive tape. Apply the same adhesive tape to the air intakes of the engine. Apply adhesive tape also on the oil breather tube (A) and on the terminals of the accelerator control (B).
  • Page 38 Maintenance Unscrew the earth bonding on the engine head cover and release the coil harness from the frame removing the two clamps, and extract it on the right side. Unscrew the fixing screws of the coil plates, and remo- ve them. Pull out the coils from their seat.
  • Page 39 Maintenance Operating as shown in the figure, slightly lift up the cylinder head cover. To carry out this operation, use only the work surfaces indicated. Take care to not ruin or deteriorate the motorcycle parts in the proximity of the work area. Proceed with the removal of the cylinder head cover.
  • Page 40 Maintenance Utilising a syringe, remove the surplus oil that is left in the various niches in proximity to the valve cups. Proceed with the removal of the timing wheel cover by unscrewing the five fixing screws. Rotate the camshaft by turning the central nut in an anti-clockwise direction to bring piston N°...
  • Page 41 Maintenance Check the timing of the engine by ensuring that the incision stamped on tooth (A) of the timing wheel is in line with the “tooth” (B) that is present on the engine casing. The following photograph illustrates clearly the correct position.
  • Page 42 Maintenance Continue measuring the play as illustrated in the figu- The correct measuring of the play is a funda- mental operation for the correct functioning of the engine. - 28 -...
  • Page 43 Maintenance Carry out the measuring of the play of the following val- ves: Cylinders 1 and 2 intake valves (number° 1,2,3,4) Cylinders 1 and 3 exhaust valve (number 11,12,15,16). Scrupulously, make a note of the order of the values measured in the form of a table. For example, here is a hypothesis of a table in which are written the various values measured.
  • Page 44 Maintenance The progressive numeration of each valve is illustrated SCARICO EXHAUST in the photograph on the right. Note the anti-clockwise direction of the numeration. ASPIRAZIONE INDUCTION To facilitate the operation, it is possible to note befo- rehand and in order the play values revealed on the strip of adhesive tape applied to the openings of the air intake conduits.
  • Page 45 Maintenance Check again the timing of the engine, ensuring that the incision stamped on the timing wheel is aligned with the “tooth” on the engine casing. Continue with the measuring of the play of the fol- lowing valves: Cylinders 3 and 4 intake valves (n° 5,6,7,8) Cylinders 2 and 4 exhaust valves (n°...
  • Page 46 Maintenance Valve play between the valve cup and the cam Camshaft Upper cup for the springs Adjustment pad Valve cup Valve The play values measured between the valve cup and cam must be the following: For all intake valves 0,15 ÷ 0,24 mm For all exhaust valves 0,20 ÷...

  • Page 47: Spark Plugs

    Maintenance Timing chain, mobile timing chain guide and timing chain tensioner Timing chain and mobile timing chain guide: Check First 1000 kilometres and then every 12000 kilome- tres Substitute Every 36000 kilometres Timing chain tensioner: Check/substitute Every 12000 kilometres To disassemble these parts and not being a part of nor- mal maintenance, it is necessary to proceed as descri- bed in the overhaul section of the F4 workshop engine manual (Part code 8000A1592).

  • Page 48: Fuel Filters

    Maintenance Electrode condition 12 N•m Check the electrodes for wear or burning. If they are extre- mely used or burnt, substitute the spark plugs. Also sub- stitute the spark plugs in the case of breakage of the cera- mic isolation or damage to threading. When the spark plugs are renewed, check the thread pitch size and the length of the thread.
  • Page 49 Maintenance Petrol flange assembly removal Close the tank filler cap. Invert the tank and remove nine fixing screws (1) for fixing the flange to the tank. Remove the flange assembly (2) from its seat. To pull out the flange (2) use three M6 screws (1) remo- ved previously.
  • Page 50 Maintenance Extract the complete flange assembly (1). Remove the sealing O-rings (1) of the flange (2) and clean them accurately. Check they are undamaged. If damaged, replace them with new rings. Disconnect the electric connectors of the fuel pump (1). - 36 -...
  • Page 51 Maintenance Remove the fuel probe by using a tube spanner on the fixing nut of the probe. Remove the closing screw (1) of the conduit indicated in the figure so that the remaining fuel flows out of the conduit. Remove the two CLIC R 96135 fasteners (1), placed on top of the fuel filter.
  • Page 52 Maintenance Operate as indicated in the preceding figure and remo- ve the CLIC R 96135 fastener (1). Remove the fuel filter (1). Extract the fuel pump (1) from its seat. - 38 -...
  • Page 53 Maintenance Disassemble the fuel filter (1) on the pump and blow in compressed air from inner to outer as shown in the figure. Clean the seat of the fuel pump and the fuel bowl. Remove any residue and ensure that there are no sha- vings that have originated from mechanical work.
  • Page 54 Maintenance Using fine abrasive paper clean the first threading “cre- sts”of the fuel probe seat as shown in the figure. This operation is necessary to not compromise the good condition of the gasket during the assembly phase of the probe. Place the fuel filter on the pump in according to the timing shown in the figure.
  • Page 55 Maintenance Insert a new fuel filter (1) within the pipe verifying its right placement (the arrow, marked on the exterior of the body must be oriented as shown in the figure). If necessary, utilise alcohol to facilitate the assembly. Tighten the CLIC R 96 135 fastener (2) – green colour –...
  • Page 56 Maintenance Insert the pipe on the fuel pump. Facilitate the insertion using alcohol. Assemble the CLIC R 96 135 fastener (1) – green colour – using the CLIC 205 pincers. Assemble the fuel probe (1) on the die-cast flange. When reassembling, substitute the gasket (2) with a new one and lubricate it with silicone grease.
  • Page 57 Maintenance Reconnect the electrical connectors. It is advisable to clean and degrease the contacts with the correct solvent. Curl the electrical cable (1) into a circle at least twice to contain it in the space. Place the tube (2) so that it is almost into contact with the fuel pump.

  • Page 58: Fuel Pump Assembly

    Maintenance FUEL PUMP ASSEMBLY - 44 -...
  • Page 59 Maintenance Code Q.ty Note BRUTALE ORO BRUTALE S I FRAME I I ENGINE I 8A0094275 • • 800090927 • • 800021480 • • 80A090925 • • 800090925 • • 800090939 • • 8000A1400 • • 800090919 • • 800090920 • •...
  • Page 60 Maintenance Fuel flange unit assembly Before starting the assembly of the flange to the fuel tank, check the condition of the two small overflow tubes connected to the lower part of the fuel filler cap. If these components are not in perfect condition, sub- stitute them and position the band fasteners as shown in the figure.

  • Page 61: Fuel Union Tubes

    Maintenance Insert the flange unit inside the tank and tighten the 6 ÷ 6,5 N•m nine fixing screws. Torque wrench of fuel pump flange fixing screws: 6 ÷ 6,5 N·m Proceed with the assembly of the parts removed by fol- lowing the removal operation in reverse order to that shown in chapter C “Bodywork”: •...
  • Page 62 Maintenance The fuel tube with the white CPC union is assembled on the right side of the butterfly body. The fuel tube with the black CPC union is assembled on the left side of the butterfly body. Follow the indication shown in the figure. Orientate the CPC unions as shown in the figure.
  • Page 63 Maintenance Ensure that the tubes are correctly fitted onto the metal unions of the butterfly body and check that the rubber tubes do not cover the curved section of the metal union. Position the “head” of the fastener as shown in the figu- Fix the fuel tubes to the unions of the butterfly body by utilising the CLIC R 96 135 (green colour) fasteners.

  • Page 64: Throttle Body Adjustment And Tuning

    Maintenance THROTTLE BODY ADJUSTMENT AND TUNING (Tickover check, CO synchronisation and check) Check and adjust First 1000 kilometres and then every 6000 kilome- tres The throttle body adjusting should be performed star- ting the engine of the motorcycle, therefore you should use a flue gas exhauster in order to not saturate the environment with burnt gas.
  • Page 65 Maintenance Verify the parameters of the injection-ignition system by the MDST diagnosis software. Connect the tool cable of the MDST diagnosis with the “Diagnostics” tap on the right side of the motorcycle near the expansion tank of the coolant. Start the MDST diagnosis software and go to the “Display instrument panel”...
  • Page 66 Maintenance Check the throttle angle when the throttle is completely closed. The nominal throttle opening angle is 1.7°. Huntings between 1.5° and 1.7° are allowed only if the engine is started. Huntings between 1.7° and 1.9° and between 1.3° and 1.5°...
  • Page 67 Maintenance Connect the depression pipes with the vacuometer complying with the match between the pipe and the cylinder which is connected to. In order to perform the following operations, you should provide with the specific tool kit for setting CO. Specific tool: Part code 8000A4686 Remove the sealing caps of the CO drives placed on...
  • Page 68 Maintenance Remove the seal plate and then the gearcase sealing cap. Operate the by-pass screws in order to return to a known condition. Close completely the screws and then open them for 1 turn again. Start the engine and warm it up. During this phase you should not accelerate because the high depression created in the induction lines could pipe the mercury from vacuometer.
  • Page 69 Maintenance Balance the depressions in the cylinders: the thermo- meters should get to the same height (reference level = 2). Se all engine parameters are correctly set, the position of the adjusting screws should be between 1 and 1.5 rpms from the fully closed position. Keeping the depressions aligned, adjust the engine speed (with fan connected and light on) so it is between 1100 and 1200 rpms.
  • Page 70 Maintenance The attainment of the correct CO value could involve a variation of the engine speed at minimum. In this case you should operate the by-pass screws again to return the speed to the desired value and then repeat the trimmer adjustment. After having finished the adjustment operations, perform in the order as follows: - assemble the rubber plug on the gearcase lower side;...

  • Page 71: Air Filter

    Maintenance AIR FILTER Check/substitute Every 6000 kilo- metres Certain parts must be removed in sequence before acceding to the air filter. See chapter C “Bodywork”: • Passenger seat • Rider seat • Left tank side panel • Right tank side panel •...
  • Page 72 Maintenance Check the condition of the air filter. If it is necessary to substitute it, proceed as follows: Prepare a new air filter. Check that the inside of the air filter compartment is clean and free from foreign bodies. Insert the air filter complying with the correct assembly direction shown in the figure.

  • Page 73: Bodywork

    Maintenance Before proceeding with the assembly of the air filter compartment onto the motorcycle, apply silicone grea- se to the gaskets of the air intake bell chambers. Proceed with the assembly of the parts listed below and according to the procedure described in chapter C “Bodywork”: •...

  • Page 74: Brakes And Clutch

    Maintenance BRAKES AND CLUTCH Check the levels of fluid in the systems At pre-delivery, at first 1000 kilo- metres and then every 6000 kilo- metres Check for leakages At pre-delivery, at first 1000 kilo- metres and then every 6000 kilo- metres Substitute fluid Every 24000 kilometres or at...
  • Page 75 Maintenance In order to access the back brake fluid tank you should remove the fuel tank as described in the Chapter C “Super structures”. Likewise proceed to the front brake fluid tank. Before completing the operation, clean and wash accu- rately the 3 components of the chamber cover using alcohol and blow to dry them.
  • Page 76 Maintenance Check eventual leaks and blow-bys of brake and clut- ch fluid on the unions and tubing. If any breakages are seen, substitute the damaged parts as described in chapter H “Brakes”. Brake fluid leakages are dangerous and immediately discolour painted surfaces. Before riding, check the tubes and joints of the brakes for damage and signs of leaks.

  • Page 77: Brake/Clutch/Gearchange Commands Check

    Maintenance BRAKE/CLUTCH/GEARCHANGE COMMANDS CHECK It is possible to effectuate the adjustment of the posi- tion of the levers of the front brake, the clutch and also the gearchange lever. Such adjustments have been created to optimise the grip and the movement of the commands with regards to the needs of the motorcy- clist.
  • Page 78 Maintenance Gearchange/rear brake lever adjustment To carry out the adjustment of the rear brake lever and the gearchange lever, slacken the screw (1) utilising a 5 mm.Allen key. Adjust the position according to the requirements of the rider utilising the same key and on the hexagonal hole (2).

  • Page 79: Brake Pads

    Maintenance BRAKE PADS Front brake caliper Check/substitute At the first 1000 kilo- metres and then very 6000 kilometres Check the condition and thickness of the brake pads on the pincers. Rear brake caliper The brake pads have small channels that assist in checking the wear.

  • Page 80: Dair Intake Injection System

    Maintenance After making adjustments, check that the throttle val- ves open slightly by activating the choke lever (1), as indicated in the following figure. If interventions have been carried out on the throttle bodies, the transmission of the accelerator control must be analysed not only at the accelerator handgrip but also near to the throttle bodies.

  • Page 81: Locks

    Maintenance LOCKS Check At the pre-delivery, at the first 1000 kilometres and then every 6000 kilo- metres Ignition/steering block switch This switch has four operating positions. Do not attach key rings or other objects to the ignition key that could obstruct the rota- tion of the steering.
  • Page 82 Maintenance Fuel cap lock Lift up the anti-dust cover. Insert the key, rotating it in a clockwise direction and lift up the cap. After refuelling, press the cap down and rotating the key contemporaneously to facilitate the closure. Press and hold the cap, let the key go free, bring it into a lon- gitudinal position and pull it out.

  • Page 83: Steering

    Maintenance STEERING Check and adjust At the first 1000 kilometres and then every 12000 kilo- metres Check the steering components regularly according to the above-mentioned intervals. If it is necessary to carry out adjustments, operate as described in chapter F “Suspension and wheels”. TRANSMISSION CHAIN Check At the pre-delivery, at the first 1000...
  • Page 84 Maintenance Adjust At the first 1000 kilometres and then every 6000 kilometres To adjust the chain tension, proceed as follows: Slightly loosen the 2 screws of the back wheel hub until they can freely turn. Using the special spanner as indicated in the figure, move the eccentric adjuster nut backwards or forwards respectively slackening or tightening the chain, until the correct play is reached (as described previously).
  • Page 85 Maintenance Chain lubrication Lubricate At the first 1000 kilometres and at 6000 kilometres and then at every 12000 kilometres Clean the chain with a clean cloth and/or a jet of air. The chain is the type with sealing rings (O- RING);...

  • Page 86: Tyres

    Maintenance TYRES Check pressures At the pre-delivery, at the first 1000 kilometres and then every 6000 kilometres Check wear At the first 1000 kilometres and then every 6000 kilometres If the tyre pressures are too high or too low, the ride is affected and tyre life duration is accentuated.

  • Page 87: Wheels

    Maintenance WHEELS Visual check At the first 1000 kilometres and then every 6000 kilometres (at least every tyre change) After having visually checked or following even light collision damage, it is necessary to check the planarity, the eccentricity and the ovalisation of the wheel. See the control procedures described in chapter F “Suspension and wheels”.

  • Page 88: Rear Wheel Hub

    Maintenance REAR WHEEL HUB Check and lubricate bearings Every 12000 kilometres Substitute Every 12000 kilometres To check and overhaul the rear wheel hub unit, it is necessary to carry out certain preliminary operations by consulting the relative chapters. Remove the rear wheel (see chapter F “Suspension and wheels”).

  • Page 89: Side Stand

    Maintenance Compression and extension adjustment (rear suspen- sion): CLICK! CLICK! CLICK! N.B. CLICK! CLICK! This operation can be made with the CLICK! shock absorber in position on the motorcycle. For further checks on the round joints where the rear shock absorber is atta- ched, it is necessary to carry out the pha- ses of removal described in chapter F “Suspension and wheels”.

  • Page 90: Front Fork

    Maintenance FRONT FORK Substitute oil every 24000 kilometres The front fork is vitally important for the rideability and roadholding of the motorcycle. It is therefore necessary to substitute the fork oil at the prescribed intervals. Quantity oil: about 655 cc Specified oil: - Brutale ORO / S (MY 03): SAE 5...

  • Page 91: Electrical System

    Maintenance ELECTRICAL SYSTEM Check the functioning At the pre-delivery, at the first 1000 kilometres and then every 6000 kilometres Carry out a detailed check on the various parts of the electrical system, the contacts between components and their good functioning. Consult chapter E “Electrical system”...
  • Page 92 Maintenance Turn the screw of the positive terminals and tighten them complying with the prescribed torque by using a torque wrench. Torque wrench setting: 7 ÷ 8 Nm 7 ÷ 8 N•m When the leads are mounted, replace the protection cover on the positive pole (see the figure).
  • Page 93 Maintenance Turn the screw of the negative terminals and tighten them complying with the prescribed torque by using a torque wrench. Torque wrench setting: 7 ÷ 8 N•m Before tightening, verify that the cables are correctly oriented. 7÷8 N•m At the end of assembly, ensure that the cable of the positive terminal is placed inside the structure of the back sub-frame (see the figure).

  • Page 94: Instruments And Warning Lights

    Maintenance INSTRUMENTS AND WARNING LIGHTS Luminous warning Luminous warning indication light Check At the pre-delivery, at the first 1000 indication light kilometres and then every 6000 kilo- metres The instrumentation check must be carried out com- button Tachometer pletely on all its functions as listed in the following list. If even one of the functions does not function correctly, consult chapter E “Electrical system”...
  • Page 95 Maintenance Multi-function display 10 Speedometer The speedometer indicates the speed. The value of the scale can be written in kilometres per hour (k.p.h.) or miles per hour (m.p.h.). The highest value on the scale is 299 k.p.h. (185 m.p.h.). 11 “SET” button If pressed, the “SET”...
  • Page 96 Maintenance Modifications to the display functions Modifications can be made to the clock function, the tripmeter function and the thermometer function. This operation must be effectuated with the engine switched on and the gears in neutral. Clock (hours and minutes) Repeatedly press the starter button until the visualisa- tion of the hour appears.
  • Page 97 Maintenance Press the starter button to pass from kilometres per hour to miles per hour and vice versa. Varying the measuring unit of the speedometer automatically varies also the mileometer (total and partial). Press the “SET” button. The measuring unit of the ther- mometer starts to flash.
  • Page 98 Maintenance Resetting of the tripmeters The values of the “TRIP 1” and “TRIP 2” can be reset as follows. Press the starter button to activate the “TRIP 1”. Press the starter button for more than four seconds. The value will start to flash. Press the starter button for less than four seconds;...

  • Page 99: Lights

    Maintenance LIGHTS Check At the pre-delivery, at the first 1000 kilometres and then every 6000 kilo- metres If any of the warning lights or the main lights are burnt out, replace them as follows. Dipped headlamp – bulb substitution Remove the two side fixing screws (1) of the front headlight.
  • Page 100 Maintenance Put the headlamp on a table in order to perform the fol- lowing operations. Remove the back screw of the headlamp. Remove the front part of the headlamp from its support shell. Disconnect the connector of the dipped headlight. Remove the protection cover.
  • Page 101 Maintenance Dipped headlight – Replacing bulb Turn the bulb of the dipped headlight counterclockwise and extract it from its seat. Disconnect the connector from the bulb. Do not touch the glass of the bulb with your hands. In case of contact clean using a degreasing product.
  • Page 102 Maintenance To extract the bulb press it counterclockwise. Insert the new bulb pressing and turning it clockwise. Reassemble the glass and retighten the fixing screw. Rear direction indicators – bulb substitution Remove the fixing screw. Remove the glass. To extract the bulb press it counterclockwise. Insert the new bulb pressing and turning it clockwise.
  • Page 103 Maintenance Rear light/stop light – bulb substitution Lift the passenger seat. Extract the bulb holder, rotating it in an anti-clockwise direction. To extract the bulb, press it down and rotate it in an anti-clockwise direction. Insert the new bulb pressing and turning it clockwise. Reinsert the bulb holder and rotate it in a clockwise direction.
  • Page 104 Maintenance Following the procedure shown in the figure, lower the cable guide separating it from the upper supporting surface. Extract the lamp holder of the number plate light from its seat. Extract the bulb taking it out from the lamp holder. Insert the new bulb.
  • Page 105 Maintenance The fuses are situated on the right side of the motorcy- cle; to reach them you should disassemble the right side panel fixed on the tank. Remove the cover. Turn the ignition switch on “OFF” before checking or replacing the fuses in order to avoid accidental short circuits with conse- quent risk to damage other electric compo- nents.

  • Page 106: Front Headlamp

    Maintenance Replace the burnt fuse and reassemble the cover. Remember that two spare fuses are available in the toolkit. Never use a fuse having an adjustment diffe- rent from the instructions in order to avoid from damaging the electrical system of the motorcycle with the consequent fire risk.
  • Page 107 Maintenance Adjusting front headlight Place the motorcycle 10 metres from a vertical wall. Ensure that the ground is even and that the optical axis of the projector unit is perpendicular to the wall. The motorcycle must be in a vertical position.. Measure the height of the centre of the beam from the ground and mark it with a cross on the wall using a piece of chalk.
  • Page 108 Maintenance - 94 -...
  • Page 109 Bodywork SECTION Revision 0 - 1 -...
  • Page 110 Bodywork SUMMARY FAIRING ASSEMBLY ..........................Page 3 DISASSEMBLING FRONT HEADLAMP....................Page 4 DISASSEMBLING INSTRUMENTATION PANEL .................Page 5 DISASSEMBLING HANDLEBAR ......................Page 6 DISASSEMBLING HEADLIGHT SUPPORT ..................Page 7 FUEL TANK..............................Page 8 DISASSEMBLING FUEL TANK SIDE PANELS ...................Page 9 FUEL TANK REMOVAL.........................Page 10 AIR FILTER COMPARTMENT........................Page 15 AIR FILTER COMPARTMENT REMOVAL ....................Page 16 TAIL UNIT..............................Page 20 TAIL UNIT REMOVAL..........................Page 21...

  • Page 111: Fairing Assembly

    Bodywork FAIRING ASSEMBLY - 3 -...

  • Page 112: Disassembling Front Headlamp

    Bodywork DISASSEMBLING FRONT HEADLAMP Disassemble the two fixing screws of the headlamp. Release the headlamp from the support for the lumi- nous beam height control. Disconnect the electric connection (1) and remove the headlamp. - 4 -...

  • Page 113: Disassembling Instrumentation Panel

    Bodywork DISASSEMBLING INSTRUMENTATION PANEL Unscrew the fixing screws and remove the instrumen- tation panel cover by acting in the shown direction. Release the connector (1). Unscrew the fixing screw of the instrumentation panel and withdraw it from the support. - 5 -...

  • Page 114: Disassembling Handlebar

    Bodywork DISASSEMBLING HANDLEBAR Before performing this operation, you should prelimi- narily carry out the disassembling of the front headlight and the instrumentation panel as described in the pre- vious pages. Disconnect the connectors. Withdraw the wiring from the headlight support hooks. Disconnect the warning horn.

  • Page 115: Disassembling Headlight Support

    Bodywork Unscrew the four fixing screws of the handlebar U bolt. Remove the handlebar with the U bolt. 20 N•m During the reassembly, you should pay attention to the right positioning of the U bolt in regard to the handlebar. This is made using a pin that you have to insert in the right seating of the handlebar.

  • Page 116: Fuel Tank

    Bodywork FUEL TANK - 8 -...

  • Page 117: Disassembling Fuel Tank Side Panels

    Bodywork Before removing the fuel tank you should preliminarily remove passenger and rider seats as described at the paragraph “Disassembling tale unit” of this chapter. Remove the ignition commutator protection by unscrewing the two fixing screws (1). DISASSEMBLING FUEL TANK SIDE PANELS Operate on the left side of the motorcycle.

  • Page 118: Fuel Tank Removal

    Bodywork Release definitely the side panel by moving it towards the rear part in order to release it from the special rub- bered screw (1) fastened to the fuel tank. Make the same operations in order to remove the right side panel.
  • Page 119 Bodywork Operate on the right side. Unscrew and remove the special rubbered screw (1) on the tank support. Unscrew and remove the two support fixing screws (1) of the tank support. Make the same operations on the left side of the motorcycle in order to remove the tank support.
  • Page 120 Bodywork Lift and lean the fuel tank on a side in order to easily work on the rapid unions on the fuel pump flange. In order to make the unions disengagement N.B. operation from the fuel pump flange easier it’s recommended the presence of two ope- rators, one that works on the tank support and the other on the rapid unions release.
  • Page 121 Bodywork Disconnect the connector of the fuel flange pump (1) of the main wiring. Withdraw the fuel breather pipe (1) connected to the three-way union. Removing of the fuel tank plug Insert the motorcycle key in the fuel plug lock, rotate clockwise and open the plug.
  • Page 122 Bodywork Unscrew and remove the three screws (1) and the safety screw (2). During the reassembly of the fuel tank plug make the same operations in the opposite direction in regard to disassembling ones by tightening them at the descri- bed torque and apply the indicated brakethread.

  • Page 123: Air Filter Compartment

    Bodywork AIR FILTER COMPARTMENT - 15 -...

  • Page 124: Air Filter Compartment Removal

    Bodywork AIR FILTER COMPARTMENT REMOVAL Before removing the air filter compartment you should primarily remove the fuel tank as described in the para- graph “Tank” of this chapter. Unscrew and remove the fixing nut (1) of the earth wiring of the gearcase. Disconnect the connector (1) of the temperature sen- sor and the air pressure from the sensor.
  • Page 125 Bodywork Disconnect the connection to the gearcase from the main wiring. Release the fixing springs (1) of the air filter compart- ment box to the throttle body. Unscrew and remove the two side fixing screws (1) of the air filter compartment to the frame. - 17 -...
  • Page 126 Bodywork Disconnect the breather piping (1) from the block. Unscrew and remove the two fixing screws (1) and the air filter compartment locking support (2). Remove the air filter compartment from the throttle body. - 18 -...
  • Page 127 Bodywork During the reassembling make the same operations of the disassembling paying attention to tighten the fixing screws (1) of the ignition commutator to the described torque wrench. Torque wrench of the air filter compartment fixing screws and locking support: 8 ÷ 10 N•m Apply Loctite 243 8÷10 N•m...

  • Page 128: Tail Unit

    Bodywork TAIL UNIT - 20 -...

  • Page 129: Tail Unit Removal

    Bodywork TAIL UNIT REMOVAL Insert the ignition lock key in the opening seat lock on the left side of the motorcycle and rotate it clockwise. In the meantime push lightly on the passenger seat. The lock will be released. Remove the passenger seat. Release the fixing clip of the rider seat and remove it from its seat by lifting it.
  • Page 130 Bodywork Unscrew and remove the three fixing screws (1) of the tale unit panels on both sides paying attention to reco- ver the nylon washers (2). After that remove the side panels. Extract the lamp holder of stop and side light from its seat.
  • Page 131 Bodywork Unscrew the four fixing screws of the rear part tale unit. Remove the rear part of the tale unit. Release the electric connector and remove the lamp holder of the tail and stop light with the wiring. - 23 -...

  • Page 132: Under-Tail Assembly

    Bodywork UNDER-TAIL ASSEMBLY - 24 -...

  • Page 133: Disassembling Under Tale Unit

    Bodywork DISASSEMBLING UNDER TALE UNIT Disassemble the passenger and rider seats and the side panels as described in the previous paragraph “Disassembling tale unit”. Disconnect the connections of the direction indicator and of the number plate light. Unscrew the three fixing screws of the number plate holder.
  • Page 134 Bodywork Unscrew the fixing screws of the battery connections and remove it from its seat. Release the connector from the solenoid starter. Remove the fixing screw of the starter. - 26 -...
  • Page 135 Bodywork Unscrew the under tale unit fixing screws. Remove the under tale unit. - 27 -...
  • Page 136 Bodywork - 28 -...
  • Page 137 Air intake injection system SECTION Revision 0 - 1 -...
  • Page 138 Air intake injection system SUMMARY INJECTION-IGNITION SYSTEM ......................PAGE 3 INJECTION SYSTEM TECHNICAL CHARACTERISTICS ...............PAGE 3 INJECTION TIME (INJECTION VOLUME)....................PAGE 3 INJECTION TIME COMPENSATION......................PAGE 4 INJECTION ARREST CONTROL ......................PAGE 4 MOTOR CONTROL - POSITION OF THE PARTS..................PAGE 6 FUEL PUMP CONTROL SYSTEM ......................PAGE 7 COMPONENTS ............................PAGE 9 SENSORS ..............................PAGE 11 ENGINE PICK-UP ............................PAGE 14...

  • Page 139: Injection-Ignition System

    Air intake injection system INJECTION-IGNITION SYSTEM The injection-ignition system is of the "alpha/N” type. The motor r.p.m. and the throttle position are used as main parameters to measure the amount of intake air to find the amount of fuel to be injected. The amount of intake air for each cycle depends on the density of the air in the intake collector, the single displa- cement and the volumetric efficiency: this last is determined experimentally on the engine for the entire functio- ning range (rounds and engine load) and it is stored in the dimensioned plans (maps) inside the EPROM of the...

  • Page 140: Injection Time Compensation

    Air intake injection system INJECTION TIME COMPENSATION The various sensors allow the injection time (volume) compensations to be carried out on the basis of the following signals. SIGNAL DESCRIPTION When the atmospheric pressure is low, the sensor ATMOSPHERIC PRESSURE SENSOR SIGNAL sends a signal to the ECU to reduce the injection time (volume of the fuel injected) to compensate the lower presence of oxygen in the atmosphere.
  • Page 141 Air intake injection system IGNITION SYSTEM DESCRIPTION The system belongs to the family of integrated systems of digital electronic ignition with advance static timing and electronic fuel injection of the semi-phased intermittent type (injected and ignition simultaneously to cylin- ders 1-4 and 2-3). This ignition system consists of an engine crankshaft position sensor (pick-up), an ECU, four ignition coils of the top plug type and four spark plugs.
  • Page 142 Air intake injection system - 6 -...

  • Page 143: Fuel Pump Control System

    Air intake injection system FUEL PUMP CONTROL SYSTEM When the ignition switch is switched to the "ON" position, the current from the battery reaches the motor of the fuel pump via the side stand relay and the pump relay thereby switching on the motor. As the CPU possesses a timer function, the pump motor stops turning three seconds after the ignition switch has been brought to the "ON"...
  • Page 144 Air intake injection system Fuel feed system The fuel feed system consists of the tank, pump, filter, feed tube, feed tubes (including the fuel injectors), regu- lator of the pressure and the fuel return tube. The fuel in the tank is pumped into the feed tubing at a controlled pressure by the relative regulator and maintained at a certain constant value higher than the suction generated by the motor.

  • Page 145: Components

    Air intake injection system COMPONENTS Fuel pump The electric fuel pump that is situated inside the fuel tank consists of an electric motor, of the rotor, impeller, con- trol valve and pressure release valve. The ECU controls the ON/OFF condition as described in the section FUEL PUMP CONTROL SYSTEM. When electrical energy is supplied to the pump, the motor switches on and the impeller activates.
  • Page 146 Air intake injection system Fuel pressure regulator The fuel pressure regulator is a diaphragm pressure release valve that consists of a diaphragm, spring and valve. It always maintains the pressure of the fuel sent to the injector at 3.0 kg/cm2 (300 kPa). When the pressure of the fuel rises above 3.0 kg/cm2 (300 kPa) the excess fuel opens the valve of the regulator and therefore can return to the fuel tank.

  • Page 147: Sensors

    Air intake injection system SENSORS Atmospheric air temperature/pressure The air intake sensor is situated on the right side of the air filter compartment and indicates both the atmo- spheric pressure and the air temperature. Intake air pressure sensor The sensor reveals the pressure of the intake air and this pressure is therefore converted into voltage that is sent to the ECU.
  • Page 148 Air intake injection system Intake air temperature sensor The temperature of the intake air is found measuring the resistance of the Thermistor. The resistance value read is proportionate to the voltage read by the ECU. The volume of fuel injected increases when the intake air temperature is low. The resistance of the Thermistor increases when the air temperature is low and diminishes when the temperatu- re is high (NTC type sensor).
  • Page 149 Air intake injection system Throttle body position The sensor of the throttle position is situated on the right side of the throttle body. This sensor is a potentiometer with a resistance which varies according to the opening angle of the accelera- tor.

  • Page 150: Engine Pick-Up

    Air intake injection system ENGINE PICK-UP The r.p.m./TDC sensor is of an inductive type and is situated on the left side of the motorcycle. To check this component it is necessary to identify the relative connector positioned as shown in the figure, inside the frame on the right side of the motorcycle.

  • Page 151: Actuators

    Air intake injection system ACTUATORS Fuel injector The fuel injector consists of a solenoid, piston, needle valve and a filter. The injector is a small electromagnetic injection nozzle that injects fuel into the carburettor according to the signal coming from the ECU. When the solenoid is agitated by the ECU, it becomes an electromagnet and attracts the piston.

  • Page 152: Diagnostics System

    Air intake injection system DIAGNOSTICS SYSTEM Ignition and injection system diagnostics For the diagnosis of the ignition and injection system A Weber-Marelli diagnostic software is available which is capable of identifying and recording the faults present or that were present previously on the motorcycle. This software is equipped with a guide book for the use of the software itself to carry out checks on each indivi- dual component of the system.

  • Page 153: Injection System - Electrical Diagram

    Air intake injection system INJECTION SYSTEM - ELECTRICAL DIAGRAM - 17 -...
  • Page 154 Air intake injection system MV Agusta Brutale Oro – S Engine control unit pinout Description Type of signal cylinders 1-4 coil control power output Latch relay control digital output Injectors 2-3 control power output engine enabling from safety logics digital input...

  • Page 155: Electrical System

    Electrical system SECTION Revision 0 - 1 -...
  • Page 156 Electrical system SUMMARY CONNECTORS ............................PAGE 3 COUPLINGS ..............................PAGE 3 FUSES................................PAGE 3 SEMICONDUCTOR PARTS........................PAGE 4 ELECTRICAL DIAGRAM ........................PAGE 5 PARTS LIST ..............................PAGE 6 BATTERY ..............................PAGE 7 INITIAL BATTERY CHARGE ........................PAGE 7 BATTERY ASSEMBLY..........................PAGE 7 CHARGING SYSTEM..........................PAGE 12 BATTERY EFFICIENCY CHECK ......................PAGE 20 CPU ...............................PAGE 22 FUNCTION DIAGRAM..........................PAGE 22 STARTER SYSTEM ...........................PAGE 23...

  • Page 157: Connectors

    Electrical system CONNECTORS • When a connector is connected, check that it clicks into position. • Check the connector for corrosion, dirt or a broken cover. CLICK COUPLINGS CLICK • Block couplings – ensure that the block is released before disconnecting it to push it completely home when connecting it.

  • Page 158: Semiconductor Parts

    Electrical system SEMICONDUCTOR PARTS INCORRECT • Pay special attention to not drop parts incorporating semiconductors (ECU, instrument panel, CPU). • When checking these components, carry out the instruction strictly. The lack of using the correct pro- cedure can cause grave damage. - 4 -...

  • Page 159: Electrical Diagram

    Electrical system ELECTRICAL DIAGRAM - 5 -...

  • Page 160: Parts List

    Electrical system PARTS LIST Parts list Parts list Parts list Ref. Description Ref. Description Ref. Description Solenoidd Instrument panel 17-18 Number plate light Air temperature/pressure sensor Injectors Iniettori 19-20 Right indicator Left indicator Butterfly potentiometer Left indicator Horn Water temperature sensor – CPU Diagnostic connector Water temperature sensor for instrument ther- Oil switch...

  • Page 161: Battery

    Electrical system BATTERY The battery mounted on this motorcycle is a sealed battery therefore no maintenance is required. The batteries recommended are the following: - YUASA YTZ10-S (pre-activated). INITIAL BATTERY CHARGE Proceed with charging following the method on the packet that the battery came in or as indicated in the following table.
  • Page 162 Electrical system Remove the passenger seat as shown in the figure. Rotate the rider seat fastener as shown in the figure. Lift up the rider seat and remove it. - 8 -...
  • Page 163 Electrical system Insert the battery into the appropriate compartment. The initial battery charge should be carried out before mounting it on the motorcycle. Battery terminal assembly Assemble the two positive (+) terminal leads on the relative battery pole, respecting the order shown in the figure.
  • Page 164 Electrical system When the terminals are mounted replace the protec- tion cover on the positive pole (see figure). Connect the two negative (-) terminal leads to the rela- tive pole of the battery respecting the placing shown in the figure. Rotate the screw of negative terminal leads and tighten to the prescribed torque, using a torque wrench.
  • Page 165 Electrical system After the assembly operation, make sure that the positive terminal cable is positioned correctly inside the rear frame unit (see figu- re). PLACEMENT AND ASSEMBLY OF TERMINALS (WIRE TERMINALS) ON THE BATTERY POSIZIONAMENTO E MONTAGGIO DEI TERMINALI (CAPICORDA) SULLA BATTERIA. NEGATIVE WIRE (-) CAVO NEGATIVO (-) NEGATIVE POLE (-)

  • Page 166: Charging System

    Electrical system CHARGING SYSTEM The system of the charging circuit illustrated as follows is substantially composed of a generator and a rectifier/regulator, enclosed in one component. The alternating current (AC) is transformed into direct current (DC) by the rectifier, regulated and therefore utilised for charging the battery.
  • Page 167 Electrical system In the preceding diagram is illustrated the complete charging circuit. The input circuit of the regulator includes the integrated M-IC that, being complex in its various functions will be simply indicated as M-IC. (1) Ignition switch “ON” with engine off. Ignition Switch Stator coil...
  • Page 168 Electrical system (2) Recharging (voltage less than the regulated voltage). Ignition Switch Stator coil Charge Lamp M.IC Rotor coil IC Regulator Once the engine is switched on, the M-IC makes the Tr1 pass from an intermittent “ON” and “OFF” condition to a stabilised “ON”...
  • Page 169 Electrical system (3) Recharge (voltage more than the regulated voltage). Charge Current Ignition Switch Stator coil Charge Lamp M.IC Rotor coil IC Regulator The moment in which the Tr1 is stabilised in the “ON” position the voltage at terminal B increases and when the voltage at terminal S exceeds the regulated voltage (approximately 14.5V at 25°), the I-MC realises it and puts the Tr1 in the “OFF”...
  • Page 170 Electrical system (4) Rotor coil disconnected. Charge Current Ignition Switch Stator coil Charge Lamp M.IC Rotor coil IC Regulator If the rotor coil is disconnected whilst the generator is functioning, the generator interrupts the current and the vol- tage at terminal P goes to zero. The M-IC reveals this condition and through the Tr3 switches on the warning light.
  • Page 171 Electrical system (5) Disconnection of terminal S of the regulator. Charge Current Ignition Switch Stator coil Charge Lamp M.IC Rotor coil IC Regulator If a reference voltage does not arrive at terminal S whilst the alternator is functioning, the M-IC reveals it and through Tr3 switches on the warning light.
  • Page 172 Electrical system (6) Terminal B disconnected. Charge Current Ignition Switch Stator coil Charge Lamp M.IC Rotor coil IC Regulator Connettore a 4 vie 4 ways connector If terminal B is disconnected whilst the alternator is functioning, the voltage of the battery gradually drops until it starts discharging.
  • Page 173 Electrical system A list of possible problems that could occur when the warning light is switched on. Incorrect contact at terminal B or the 4- Repair the fault. way coupling; interruption of the system The light still remains on. including the fuses or short circuit. There is a short circuit between terminal Repair the fault.

  • Page 174: Battery Efficiency Check

    Electrical system BATTERY EFFICIENCY CHECK Battery current loss check • Remove the tail unit as described in chapter C “Bodywork”. • Turn the ignition switch to the “OFF” position. • Disconnect the cable from the negative (-) pole of the battery.
  • Page 175 Electrical system Charge feed check • Remove the tail unit • Switch on the engine and run it at 2000 r.p.m. with the light switch in the “ON” position and the selector on main beam Hl. Measure the voltage between the positive (+) and negative (-) terminals of the battery with a multi-tester.

  • Page 176: Cpu

    Electrical system The CPU includes a group of functions previously performed by other components of the motorcycle. This allowed to simplify wiring and to reduce connections. The general reliability of the unit is enhanced and overall weight is reduced. FUNCTION DIAGRAM ELECTRICAL SYSTEM IGNITION SWITCH FUEL-INJECTOR-COIL PUMP...

  • Page 177: Starter System

    Electrical system STARTER SYSTEM The diagram below represents the starter system. KILL INTERRUTTORE SISTEMA - ACCENSIONE IGNITION INJECTION SWITCH SPEGNIMENTO INIEZIONE SYSTEM 7.5A POSITIVE TER- POSITIVO MINAL – BAT- BATT. TERY N.O. IN CENTRALINA ECU 1.6 M 1.6M N.O. BATT +BATTERY + BATTERIA STARTER...
  • Page 178 Electrical system - 24 -...
  • Page 179 Electrical system - 25 -...
  • Page 180 Electrical system - 26 -...
  • Page 181 Electrical system - 27 -...
  • Page 182 Electrical system - 28 -...
  • Page 183 Electrical system - 29 -...
  • Page 184 Electrical system - 30 -...
  • Page 185 Electrical system - 31 -...

  • Page 186: Fuses

    Electrical system Electrical system FUSES The fuses are situated on the right side of the motorcy- cle. To reach them it is necessary to remove the tank side panel and the cover. Substitute the burnt fuse and replace the cover (find the electrical fault before replacing the fuse).

  • Page 187: Starter Motor Check

    Electrical system STARTER MOTOR CHECK If a fault has been diagnosed in the starter motor, it is necessary to proceed as follows with the check: • Connect a tester between earth and the starter motor terminal. • Check that there is continuity between the positive pole and the engine earth.
  • Page 188 Electrical system Starter relay check Remove the rider seat, disconnect the battery. Unhook the connector from the starter relay. Unscrew the fixing screw of the relay. Disconnect the cables of the starter motor and the positive cable of the battery from the relay. - 34 -...

  • Page 189: Ignition/Side Stand Safety System Parts Check

    Electrical system Apply 12 volts to the terminals (1) and (2) of the relay and check the continuity between terminals B-M. Do not apply the battery voltage to the starter relay for more than five seconds to avoid overheating and therefore damaging the winding. - Using a multi-tester, check that the winding is on open circuit or if a resistance is present.

  • Page 190: Gearchange Position Switch

    Electrical system GEARCHANGE POSITION SWITCH The connector of the gearchange position switch is placed in the proximity of the side stand and motorcy- cle speed sensor connectors. The connector of the gearchange position switch dif- fers from the side stand connector since it is identified by an S marked on the electric system sheathing.

  • Page 191: Spark Plugs

    Electrical system If it is necessary to substitute the switch proceed by unscrewing the two fixing screws. SPARK PLUGS To accede to the ignition spark plugs, it is necessary to remove the following components: • Tail unit • Left side panel •...
  • Page 192 Electrical system Unscrew the fixing screws of the coil plates and remo- ve them. Remove the coils from their seats. When reassembling the coils, take care to connect the map connector correctly. If not connected or if connected incorrectly, it could cause damages to the coils themselves.
  • Page 193 Electrical system Remove the relative connector to the right hand control group as indicated in the figure. Remove the plug part of the connector. With the switch in the “RUN” position, check the conti- nuity between pins (1) and (2). - 39 -...

  • Page 194: Instrumentation

    Electrical system Impianto elettrico INSTRUMENTATION If faults are found in the instrumentation, it is necessary to check the main wiring and the various components related to the instrumentation. To carry out the various checks, remove the instrument panel cover, then move aside the rubber cap and the connector situated behind the instrumentation.

  • Page 195: Oil Pressure Sensor

    Electrical system OIL PRESSURE SENSOR With the engine switched off, it is necessary to find continuity between the terminal of the sensor and the earth of the motorcycle (as shown in the figure). With the engine switched on, the contact must be open.

  • Page 196: Instrument Panel Water Sensor

    Electrical system INSTRUMENT PANEL WATER SENSOR Connect a resistance between the two connections of the connector as shown in the table. Turn the ignition key to the "ON" position. At this point the display should indicate the Temperature relative to the resistance applied. It is sufficient to carry out the test at 50°...

  • Page 197: Left Direction Indicator

    Electrical system LEFT DIRECTION INDICATOR If the left direction indicator warning light does not func- tion, there must be the presence of voltage input inter- mittently between pin (13) and pin (20). If the presence of input voltage is verified, the conti- nuity between pin (13) of the instrument panel and pin (5) of the left hand control connector must be checked.

  • Page 198: Cooling Fan System

    Electrical system If the fuse in question is in good condition, proceed with the check of the speed sensor as follows: 1) Remove the sensor from the motorcycle as descri- bed in the “F4 workshop engine manual (Code 8000A1592). 2) Disconnect the connector, check that there 10 kΩ is measured between terminals (1) and (2) of the con- nector.

  • Page 199: Klaxon

    Electrical system KLAXON A fault in the klaxon system should be checked at various points: . Check the condition of fuse 11 in the fuse box on the right side of the motorcycle. . If the fuse is in good condition, disconnect the con- nector of the left control and check the continuity between contact 34 of the control with the klaxon but- ton pressed as in the following page under “Switches”.

  • Page 200: Switches

    Electrical system SWITCHES Check the continuity of each switch with a tester. If there is any anomaly, substitute the respective switch unit with a new one. - 46 -...

  • Page 201: Suspension And Wheels

    Suspension and wheels SECTION Revision 0 - 1 -...
  • Page 202 Suspension and wheels SUMMARY FRONT WHEEL ............................PAGE 3 FRONT WHEEL REMOVAL.........................PAGE 4 FRONT FORK.............................PAGE 10 FRONT FORK OVERHAUL ........................PAGE 11 STEERING ASSEMBLY ..........................PAGE 23 STEERING ASSEMBLY OVERHAUL ....................PAGE 24 REAR SUSPENSION AND FORK ......................PAGE 29 MONO-ARM FORK REMOVAL AND OVERHAUL ..................PAGE 36 REAR WHEEL HUB ...........................PAGE 44 REAR WHEEL REMOVAL ........................PAGE 45 MOTORCYCLE SET-UP ADJUSTMENT ....................PAGE 58...

  • Page 203: Front Wheel

    Suspension and wheels FRONT WHEEL N·m 20 ÷ 22 40 ÷ 44 5 ÷ 7 Torque Kg·m pressure ft·lb Operation Description BRUTALE ORO BRUTALE S FRONT WHEEL Material Magnesium alloy Aluminium alloy Dimensions 3.50” x 17” 3.50” x 17” FRONT TYRE Dimensions 120/65-ZR 17 (56 W) Brand and type...

  • Page 204: Front Wheel Removal

    Suspension and wheels Before proceeding with the removal and overhaul of the components relative to the front suspension, it is advisable to remove beforehand the front mudguard as described in detail in chapter H “Brakes”. Place the motorcycle on the rear stand. Special tool: N.
  • Page 205 Suspension and wheels Remove the screw (1) on both front wheel/fork attach- ments. During this operation, it is necessary to sup- port the wheel. Front wheel bearing check With the wheel spindle still mounted to the wheel, rota- te the wheel to check that the bearings are not pitted and rotate with a smooth action.
  • Page 206 Suspension and wheels Utilise the special tool to extract the bearings. To assemble the tool, it is necessary to remove the screw (1) and extract the wheel spindle (2); remove the nut (3) and the flange (4). Before substituting the bearings as indica- ted above it is advisable to remove the brake discs as indicated in chapter “Brakes”...
  • Page 207 Suspension and wheels Check that the ends of the aluminium spacer and the seats of the bearings on the wheels are not scored or marked. Reassembly – front wheel bearings Before proceeding with the reassembly, accurately clean the bearing seats in the wheel hub. Mount a bearing onto the special tool.
  • Page 208 Suspension and wheels Assemble the other bearing and the guide. Insert the guide spacer and utilising a press, squeeze down the bearings. Proceed as illustrated in the figure. Attention: the wheel bearings should be mounted with little interference but should the action of the press be blocked in any way, release the press.
  • Page 209 Suspension and wheels Wheel spindle check Place the wheel spindle on two v-prisms on a flat sur- face. Utilising a dial gauge, check that the eccen- tricity in the central part does not exceed 0.05 mm. Wheel assembly If the front tyre is substituted, before assem- bling the wheel it is necessary to balance the wheel following the indications in page 62.

  • Page 210: Front Fork

    Suspension and wheels FRONT FORK N·m 8 ÷ 10 8 ÷ 9 16 ÷ 18 22 ÷ 24 20÷22 Torque Kg·m pressure ft·lb Operation Description Brutale ORO Brutale S FRONT SUSPENSION Type Hydraulic telescopic forks with the stems positioned upside down, equipped with a system of external adjustment for extension, compression and spring preload Ø...

  • Page 211: Front Fork Overhaul

    Suspension and wheels FRONT FORK OVERHAUL Remove the front wheel as described in the paragraph ”Front wheel removal” of this Chapter. Stem removal Slacken the screw (1) of the steering head and the three screws (2) of the steering base. During this phase, support the stem.
  • Page 212 Suspension and wheels Slacken the fork cap (1). Completely unscrew the cap and lower the sleeve as shown in the figure. This operation must be carried out keeping the stem in a vertical position. Unscrew the cap. Using the key, adjust the spring pre- load adjuster while blocking the rotation of the nut pla- ced on the pump rod.
  • Page 213 Suspension and wheels Remove the spring-push spacer (1) and the relative spacer ring. Slide out the spring complete with the spacer. Remove the internal rod for adjusting the extension. - 13 -...
  • Page 214 Suspension and wheels Turn the stem upside down and completely pour out the oil into a suitable container. Recover the oil in an appropriate container. Do not dispose of the used oil in the envi- ronment. Unscrew the lower central screw that fixes the pump unit.
  • Page 215 Suspension and wheels Lower the anti-dust seal (1) taking care to not damage the seat on the sleeve. Remove the retaining ring (1) with a screwdriver, taking care to not scratch the stem. Extract the sleeve from the stem by repeated blows at the end.
  • Page 216 Suspension and wheels Unscrew the hydraulic braking adjuster under com- pression. Fork assembly check Check that the sleeve does not have marks on the external part that could have repercussions inside the assembly. Ensure that the inside is completely smooth, without any scratches.
  • Page 217 Suspension and wheels Assembly oil seal and anti-dust seal. After having carefully checked all components, substi- tute those damaged and/or deteriorated. Grease the lips of the new anti-dust seal (1) and the new oil seal (2) with the appropriate grease. Apply a "sleeve"...
  • Page 218 Suspension and wheels Reassemble the hydraulic brake adjuster under com- pression into its seat by utilising a new O-ring seal. Torque pressure of the compression hydrau- lic brake adjuster : 20 N•m 20 N•m Insert the internal rod. Maintain the sleeve in a vertical position. Introduce the following amount of oil: - BRUTALE ORO / S (MY 03): 646 cc...
  • Page 219 Suspension and wheels Check that the oil level is at an “X” value from the upper edge of the sleeve, including the upper edge as well. - BRUTALE ORO / S (MY 03): X = 110 mm - BRUTALE S (MY 04): X = 105 mm Manually screw in the locknut until it reaches the end of the thread, then introduce the spring with the spacer.
  • Page 220 Suspension and wheels Place the spring-push spacer (1) and the relative washer. 20 N•m Reassemble the complete cap with a new O-ring. Tighten the cap to the prescribed torque pressure. Stem cap torque pressure: 20 N•m Reassemble the cap on the stem, tightening it to the prescribed torque pressure.
  • Page 221 Suspension and wheels Screw in and tighten the three screws (1) at the base of the steering. Carry out this assembly correctly. A casual or inexact assembly could compromise the stability and steering of the motorcycle. Assemble the right stem, in the same way as described for the left stem.
  • Page 222 Suspension and wheels Reassemble the front wheel introducing the wheel spindle inside the fork attachments. Fix the attachments with the screws (1) tightening them to the prescribed torque pressure. Torque pressure of the fork attachment screw: 20 ÷ 22 N•m 20÷22 N•m Front suspension adjustment After having correctly reassembled the entire fork...

  • Page 223: Steering Assembly

    Suspension and wheels STEERING ASSEMBLY Torque N·m 95 ÷ 100 18 ÷ 20 In contact + 10° pressu- Kg·m ft·lb Operation - 23 -...

  • Page 224: Steering Assembly Overhaul

    Suspension and wheels STEERING ASSEMBLY OVERHAUL To operate on the steering assembly, it is necessary to remove the fork stems as described in this chapter, in the paragraph “Front fork overhaul”. Then remove the components according to the following order: - front headlight;...
  • Page 225 Suspension and wheels Remove the screw ring previously slackened and remove the steering base complete with the pin. Remove the anti-dust seal, the internal bearing ring and the ball bearing ring. Eccentric steering head removal With the special tool remove the fixing screw ring of the eccentric steering head.
  • Page 226 Suspension and wheels Reassembly of the frame head steering sleeve Clean the parts accurately so that a visual check can be made of the tube and the seats. There should not be marks or lines in the bearing seats. If so, substitute the parts as necessary. Lightly grease the contact area of the frame head stee- ring sleeve (see figure) and the threaded part with Agip Grease 30.
  • Page 227 Suspension and wheels Screw ring assembly After having accurately cleaned the screw ring and the seat of the steering head on the frame, apply the pre- scribed grease both on the threading and on the coni- cal part of the screw ring, then screw it manually onto the relative seat.
  • Page 228 Suspension and wheels Assemble the steering base to the eccentric steering head. Assemble the upper ball bearing ring already greased. Assemble the internal ring of the bearing, the anti-dust sealand the screw ring of the steering pin. Steering pin tightening Screw down, without tightening, the screw ring of the steering pin.

  • Page 229: Rear Suspension And Fork

    Suspension and wheels REAR SUSPENSION AND FORK N·m 40 ÷ 44 40 ÷ 44 40 ÷ 44 50 ÷ 55 70 ÷ 75 30 ÷ 35 Torque Kg·m pressure ft·lb Operation Description BRUTALE ORO BRUTALE S REAR SUSPENSION Type Progressive with mono-arm fork and mono-shock absorber adjustable for extension, compression and spring preload Mono-arm fork Magnesium alloy...
  • Page 230 Suspension and wheels Disassembly rear shock absorber Remove the fuel tank as described in chapter C “Bodywork”. Lift up the rear part of the motorcycle (utilising a lift and safety straps) high enough to take the load off the shock absorber. Slacken the upper screw of the shock absorber (1).
  • Page 231 Suspension and wheels Raise up or lower the motorcycle utilising the lift so that the previously slackened screws are freed. Remove the pin (1) of the compensator assembly, remove the upper screw of the shock absorber. Slacken the central fixing pin of the engine (1). Slacken the rear fork pin (2).
  • Page 232 Suspension and wheels Check the length of the rear shock absorber spring. Standard spring adjustment (A): - BRUTALE ORO / S (MY 03): A = 151 mm - BRUTALE S (MY 04): A = 154 mm Check the functioning of the adjusters. The shock absorber contains high-pressure gas.
  • Page 233 Suspension and wheels Compensator assembly removal Remove the special screw (1) that fixes the compen- sator assembly of the rear suspension to the mono- arm fork. Extract the complete compensator assembly. Compensator assembly overhaul Remove the anti-dust seal (1). Check the condition of the roller bearings and if it is necessary to substitute them, utilise an extractor as shown in the figure.
  • Page 234 Suspension and wheels Rear shock absorber support plate removal Remove the three screws (1) indicated in the figure and remove the support plate (2). When reassembling, it is necessary to apply a special product to the three screws. Lightly screw them in. 40÷44 N•m Tighten the central screw first and then the other two to the prescribed torque pressure.
  • Page 235 Suspension and wheels Repeat the operation on the rear part, where the screw seat is situated in the mono-arm fork. Slide out in a forward position as shown in the figure. When reassembling, proceed in the reverse order of removal ensuring the correct positioning of the front reference peg.

  • Page 236: Mono-Arm Fork Removal And Overhaul

    Suspension and wheels Assembly rear shock absorber Accurately clean all parts. Grease the screws with Agip Grease 30 before reassembly. Insert the shock absorber from above and lightly screw in the lower screw of the shock absorber. Centralise the compensator assembly and replace the pin.
  • Page 237 Suspension and wheels Rear wheel removal Remove the rear wheel as described in the paragraph “Rear wheel removal” of this chapter. Silencers removal Unhook the two connecting springs between the silen- cers and the exhaust group. Remove the plate connecting the two silencers. - 37 -...
  • Page 238 Suspension and wheels Unscrew the screw fixing the silencers to the support. Remove the upper silencer first, then the lower one. Exhaust group removal Unhook the two connecting springs between the silen- cers and the exhaust collectors. - 38 -...
  • Page 239 Suspension and wheels Unscrew the screw fixing the compensator to the frame. Remove the exhaust compensator to remove it from the pin on the left side of the frame. Lower chain guide removal Remove the three screws of the chain guide. Remove the chain guide (1) complete with the two rear brake tube guide plates.
  • Page 240 Suspension and wheels Upper chain guard removal Remove the screw complete with ferrule. Extract the chain guard by pulling it out from the back part of the wheel (see figure) so that it is freed from its position on the mono-arm fork. Chain removal Remove the chain utilising the special tool.
  • Page 241 Suspension and wheels Mount the tool onto the chain as shown in the figure and align the punch on «A». Operate as shown in the figure. To reassemble the chain, operate in the reverse order of removal, mounting the tool with the punch as shown in the figure, aligned with «B».
  • Page 242 Suspension and wheels Bearings overhaul If it is necessary to substitute the bearings of the mono- arm because of excessive play, operate as follows: Remove the right and left spacer. Remove the Seeger retaining ring on the right side of the mono-arm.
  • Page 243 Suspension and wheels Check the condition of both bearing seats and the seat of the spacer. If the spacer is in good condition, reinsert it onto the fork from the right side. Assembly of the roller bearings and the roller bea- ring units Pre-assemble the two roller bearing units on the left side and the two ball bearings on the right hand side...

  • Page 244: Rear Wheel Hub

    Suspension and wheels REAR WHEEL HUB N·m 30 ÷ 35 20 ÷ 22 45 ÷ 50 200÷220 28÷32 220 ÷ 240 Torque Kg·m pressure ft·lb Operation Description BRUTALE ORO BRUTALE S REAR WHEEL Material Magnesium alloy Aluminium alloy Dimensions 6,00” x 17” 6,00”...

  • Page 245: Rear Wheel Removal

    Suspension and wheels REAR WHEEL REMOVAL Before checking and overhauling the rear wheel hub assembly it is necessary to carry out the following pre- liminary operations: Place the motorcycle on the rear stand. Special tool N. 800092642 Remove the fixing screws of the lower silencer. Remove the exhaust protection.
  • Page 246 Suspension and wheels Remove the retaining ring (1) of the wheel nut. Remove the rear wheel by removing the polygonal nut, using the following tools: Torque wrench 55 mm polygonal spanner Utilising a torque wrench, slacken the rear wheel nut. The polygonal fixing nut of the rear wheel has a left hand thread.
  • Page 247 Suspension and wheels After having effectuated the rear wheel removal, sup- port the motorcycle with a lift as shown in the figure. Remove the rear stand. Remove the safety ring (1) of the crown flange-fixing nut. Slacken the nut of the flange by rotating it in an anti- clockwise direction as shown in the figure.
  • Page 248 Suspension and wheels Slacken the fixings (1) of the wheel hub. With the special spanner mounted on the extension tube, pull forward the eccentric adjuster and release the chain from the crown wheel. Special tool: Eccentric adjuster spanner N. 800092854 Spanner extension N.
  • Page 249 Suspension and wheels Wheel spindle removal Remove the wheel spindle complete with the brake disc, extracting it from the right side of the motorcycle as shown in the figure. Pincer carrier flange removal Remove the Seeger retaining ring (1), the spacer ring (2), the flange (3) and the spacer ring underneath.
  • Page 250 Suspension and wheels For normal maintenance, remove the two internal spa- cers (wheel spindle seat), wash the roller bearing units, dry them and grease them. Check the condition of the ball bearings. Recommended grease: – Agip GR MU3 (Brutale ORO) –...
  • Page 251 Suspension and wheels After having heated them, remove the four brake disc carrier flange fixing screws (1) mounted with Loctite 270. Remove the flange. Recommended thread-locking fluid: Loctite Check the extra-smooth parts of the wheel spindle for wear (A). Utilising a press with an adequate punch for both the removal and assembly of the pins of the wheel drive engagement.
  • Page 252 Suspension and wheels Check Evaluate the wear condition of the crown wheel. If it is badly worn, effectuate a substitution with a new part. Slacken the five Silentblock and if necessary substitu- te them. When reassembling, grease the area that comes into contact between the flange and the crown.
  • Page 253 Suspension and wheels To assemble the brake caliper-carrying flange, carry out the following operations: Grease the O-rings and insert them into their respecti- ve seats on the flange. Assemble the rear spacer ring in contact with the hub, then the brake caliper-carrying flange (1), the second spacer ring and the Seeger retaining ring (1).
  • Page 254 Suspension and wheels Insert the spacer ring illustrated in the figure onto the wheel pin. Insert the crown wheel assembly, the second spacer ring and the wheel pin fixing nut. Tighten the nut to the prescribed torque. Rear wheel nut torque pressure: 200 ÷...
  • Page 255 Suspension and wheels Rear wheel assembly In the case of substitution of the rear tyre it will be necessary to effectuate the balancing of the wheel before assembling it. Follow the instructions indicated in page 62. Insert 1st gear. Reassemble the rear wheel. Tighten the wheel axis nut to the prescribed torque pressure.
  • Page 256 Suspension and wheels Remove the cover being careful to not extract the clut- ch control rod (it must remain inserted in the engine) and be careful to not lose the two centralising bushes indicated in the figure . Straighten the metal tongue with a flat-head drift and hammer.
  • Page 257 Suspension and wheels For reassembly, insert the pinion wheel with the chain already attached. Take a new washer, assemble it with the nut and tigh- ten to the prescribed torque pressure utilising Loctite 270 thread-locking fluid. Hammer the new washer down onto the two opposite faces of the hexagon.

  • Page 258: Motorcycle Set-Up Adjustment

    Suspension and wheels MOTORCYCLE SET-UP ADJUSTMENT This operation must be carried out when the motorcy- cle is complete and in kerb. Place the motorcycle on the rear stand. Special tool N. 800092642 Insert the setting-up arm (A) of the rear suspension (special tool) in its appropriate seats as shown in the figure.
  • Page 259 Suspension and wheels Raise the rear part of the motorcycle by using the handle and the passenger footrest, until the full exten- sion of the rear shock absorber is reached; contempo- raneously measure the distance X between the upper extremity of the rear stand and the point on the setting- up arm.
  • Page 260 Suspension and wheels At the end of the spring adjustment operation, tighten the upper lock ring as shown in the figure. Re-measu- re the distance X and X and check that the static slack r coincides with the correct value. If not, repeat the spring adjustment operation until the correct mea- surement is reached.
  • Page 261 Suspension and wheels Slacken the fixing screws (1) of the semi-connecting rods of the rear suspension. Utilising a combination wrench, vary the inter-axis between the two semi-connecting rods by adjusting the adjustment screw (1); contemporaneously, measure on the set-up rod the consequent variation of the static set-up X.

  • Page 262: Wheel Balance Check

    Suspension and wheels WHEEL BALANCE CHECK If the tyres are substituted, it is necessary to effectua- te the following operations balancing and checking the wheels. Front wheel balancing Mount the wheel onto an adequate support similar to that shown in the figure, utilising a ground pin of 35 mm diameter.
  • Page 263 Suspension and wheels Insert the polygonal nut of the balancing tool from the opposite side and screw it onto the threaded part of the tool so that the tool can be fixed to the wheel. Mount the wheel onto an adequate support similar to that shown in the figure, utilising a ground pin of 35 mm diameter.
  • Page 264 Suspension and wheels When effectuating balancing on certain makes of tyres, it is necessary to refer to the yellow mark (1) present on the side of the tyre as shown in the figure. It indicates the lighte- st point of balancing and must be situated close to the tyre valve when the tyre is moun- ted onto the wheel rim.

  • Page 265: Frame

    Frame SECTION Revision 0 - 1 -...
  • Page 266 Frame SUMMARY FRAME REMOVAL PRELIMINARY OPERATIONS .........PAGE 3 THROTTLE BODY REMOVAL .

  • Page 267: Frame Removal Preliminary Operations

    Frame FRAME REMOVAL PRELIMINARY OPERATIONS Place the motorcycle on the rear stand no. 800092642. Operating on the right side, remove the sealing cover by unscrewing the two fixing nuts. Operate in the same way to remove the left sealing cover. Remove the components in the following sequence: - Passenger and rider seat;...
  • Page 268 Frame Utilising the lift no. 800095807 equipped with the pin no. 800095808, lift up the front part of the motorcycle. Remove the components in the following sequence: - Front mudguard; - Front brake calipers; - Front wheel; - Water radiator; the procedure for removing the components indicated are described in chapter F “Suspensions and wheels”, chapter H “Brakes”...
  • Page 269 Frame Remove the two fixing screws (1) of the front headlight on the sides. Take care to slide the adjuster out of its seat when the headlight is removed from the support. Before removing the front headlight, disconnect the connector (2) placed in the rear part of the headlight. Then remove the headlight support and the instrument panel as described in chapter C “Bodywork”.
  • Page 270 Frame Protect the area around the fluid chamber with a cloth or paper. Remove the union and discharge the clutch fluid from the system into an appropriate container. Remove the steering assembly and the relative com- ponents of the front suspension as described in chap- ter F “Suspensions and wheels”.

  • Page 271: Throttle Body Removal

    Frame THROTTLE BODY REMOVAL Slacken the nut (1) fixing the accelerator control wiring to the support plate of the throttle body. Fleet the accelerator control wiring and extract the pawl (A) of the opening wiring. Carry out the same operation on the pawl of the closing wiring.
  • Page 272 Frame Slacken the bands (1) fixing the throttle body to the air intake of each cylinder. Disconnect the connections relative to the injectors of each cylinder. Remove the complete throttle body assembly. - 8 -...
  • Page 273 Frame Extract the connectors from the coils. To carry out this operation, free the secondary lock (yellow "tongue") by extracting it from its seat, then press the black "tongue" and unhook the connector. Unscrew the earth connection on the engine head cover and free the coil wiring from the frame by remo- ving the two fixing bands;...
  • Page 274 Frame Operating alternatively on both sides of the motorcycle remove the supports of the tubing for checking the suc- tion by unscrewing the screw fixing the support to the frame. Remove the two rubber bands so to free the wiring from the frame.
  • Page 275 Frame Slide out the main wiring and fold it backwards on the rear sub-frame. Fix the main wiring to the sub-frame with an elastic band. - 11 -...

  • Page 276: Frame Disassembly

    Frame FRAME DISASSEMBLY Operating in the same way on both sides of the motorcycle unscrew and remove the front screw fixing the engine cylinder head to the frame and collect the eccentric washer. Operating on the right side unscrew and remove the rear nut fixing the engine assembly to the frame.
  • Page 277 Frame Remove the screws fixing the frame tothe union plates from both sides. Remove the frame rotating the steering head housing upwards. Frame check Accurately clean the conical seats of the steering head housing. - 13 -...
  • Page 278 Frame Check that there are no marks or signs on all surfaces. Check that the area shown in the figure is not defor- med (as a consequence of accident damage). Check that there are marks of evident breakages along the frame tubes. If damage is found, substitute the frame.
  • Page 279 Frame - 15 -...

  • Page 280: Frame Control Reference Measurements

    Frame FRAME CONTROL REFERENCE MEASUREMENTS To carry out a detailed check of the frame, herewith below are the reference measurements that are of fun- damental importance for the correct condition of the frame. - 16 -...
  • Page 281 Frame Steering head housing check Check the diameter and eventual ovalisation of the 5 mm steering head housing, 5 mm from the lip of the bevel- ling as shown in the figure. Measure the ovalisation in diverse points as shown in the figure.

  • Page 282: Assembly Frame To The Motorcycle

    For the stamping and the homologation labels of the new frame, contact the MV AGUSTA service centre. Thoroughly clean the matching surfaces of the frame- engine cylinder head and frame-union plates.
  • Page 283 Frame With regards to the positioning of the cables, fasteners and various wiring consult the various tables shown in the F4 Brutale ORO - S Spare Parts Catalogue (Code 800099359). - 19 -...
  • Page 284 Frame Carry out the sequence of operations of assembly in reverse order to removal for the correct assembly of the frame to the motorcycle. Tighten the various fixings to the torque pressure shown in the following diagram. PART. DESIGN NO. DESCRIPTION DIM.
  • Page 285 Frame - 21 -...

  • Page 286: Rear Sub-Frame Removal

    Frame REAR SUB-FRAME REMOVAL After having carried out the removal of all the neces- sary components described in the previous paragraph, remove the connector (1) on the generator. Unscrew and remove the nut fixing the generator wiring to the system. Unscrew and remove the nut fixing the starter motor wiring to the starter switch.
  • Page 287 Frame Unscrew and remove the screw fixing the engine earth cable to the fixing support of the rear brake fluid tank. Once the wiring has been freed and collected as shown in the figure, it is possible to remove the rear sub-frame.
  • Page 288 Frame At this point it is possible to remove the complete sub-frame assembly from the motorcycle. Rear frame unit assembly Carry out the operation of reassembling the rear sub- frame on the motorcycle in the reverse order of remo- val, taking care to tighten the fixing screws to the pre- scribed torque pressure.

  • Page 289: Engine Removal

    Frame ENGINE REMOVAL Side stand removal Operating on the left side of the motorcycle, unscrew and remove the two fixing screws of the side stand switch. Disconnect the connector of the side stand switch from the main wiring. Disconnect the connector of the speed sensor (1) from the main wiring.
  • Page 290 Frame Remove the side stand assembly by unscrewing the three fixing screws (1). Slide the terminals of the connections out of fixing sup- port. Gearchange lever removal Unscrew the fixing screw (1) and slide out the gear- change lever (2). - 26 -...
  • Page 291 Frame Operating on the right side of the motorcycle, remove the fixing support of the rear brake fluid tank by unscrewing the fixing screw (1). Remove the rear brake pump and the relative protec- tion as described in chapter H “Brakes”. The figures show the collectors when N.B.
  • Page 292 Frame Remove the exhaust collectors fixing flanges of the cylinders 1-2-3-4 by unscrewing the fixing nuts. Unhook the union spring between the compensator and the collector of cylinders 3-4. Remove the collector of cylinders 3-4 by sliding it out of the primary compensator. - 28 -...
  • Page 293 Frame Unhook the union spring between the compensator and the collector of cylinders 1-2 and remove the col- lector by sliding it out of the primary compensator. Unhook the two connecting springs between the exhaust group and the silencers. Remove the connecting plate between the two silen- cers.
  • Page 294 Frame Unscrew the screw fixing the silencers to the support. Remove the upper silencer first, then the lower one. Unscrew the screw fixing the compensator to the frame. - 30 -...
  • Page 295 Frame Remove the exhaust compensator by removing it from the pin on the left side of the frame. Remove the chain as described in chapter F “Suspensions and wheels”. Position an appropriate lift to support the rear suspen- sion/fork assembly as shown in the figure. - 31 -...
  • Page 296 Frame Slacken the fixing screw of the front fork pin by 1 turn. Slacken the nut on the rear suspension compensator pin. Remove the engine support lower pin fixing nut. - 32 -...
  • Page 297 Frame Operating on the left side extract the engine support pin. Extract the bush shown in the figure from the union pla- tes of the frame from both sides. Remove the engine assembly from the union plates by dragging it forwards. - 33 -...
  • Page 298 Frame Operating on the right side, remove the fork pin fixing screw (1) taking care to recuperate the washer (2). Recuperate the spacer. The spacer is present on the Brutale ORO N.B. model only. Remove the right union plate. Remove the rear suspension pin fixing nut and slide out the pin from the left side.
  • Page 299 Frame Remove the fork pin (1) and the spacer (2). The spacer is present on the Brutale ORO N.B. model only. Remove the left union plate. When reassembling proceed in the reverse order of removal, taking care to apply the prescribed grease and to tighten every fixing to the torque pressure indi- cated on page 20 of this chapter.
  • Page 300 Frame - 36 -...

  • Page 301: Brakes

    Brakes SECTION Revision 0 - 1 -...
  • Page 302 Brakes SUMMARY FRONT BRAKE SYSTEM..........................PAGE 3 FRONT MUDGUARD REMOVAL ......................PAGE 4 FRONT BRAKE PADS SUBSTITUTION .....................PAGE 4 SUBSTITUTION AND BLEEDING OF THE FRONT BRAKE FLUID ..........PAGE 6 FRONT BRAKE CALIPERS SUBSTITUTION..................PAGE 10 FRONT BRAKE PUMP REMOVAL .....................PAGE 11 FRONT BRAKE LEVER REMOVAL....................PAGE 12 CLUTCH LEVER REMOVAL .......................PAGE 13 FRONT BRAKE DISCS ........................PAGE 14 FRONT BRAKE DISC REMOVAL REMOVAL ..................PAGE 15...

  • Page 303: Front Brake System

    Brakes FRONT BRAKE SYSTEM N•m 15 ÷ 20 23 ÷ 25 38 ÷ 42 16 ÷ 18 16 ÷ 18 8 ÷ 10 Torque Kg•m pressure ft•lb Operation Loctite 243 * Description BRUTALE ORO BRUTALE S FRONT BRAKE Type Semi-floating double disc with the braking area in steel Ø...

  • Page 304: Front Mudguard Removal

    Brakes FRONT MUDGUARD REMOVAL Remove the four screws of the rear attachment of the front mudguard as shown in the figure (the two lower screws are mounted with a bush). Remove the front brake tubing from the clip mounted on the attachment. Widen the attachment and slide it out of its seat.
  • Page 305 Brakes Unscrew the pad support pin as indicated in the figure. Compress the spring and extract the pin. Remove the pads. Every 6000 kilometres, check the wear of the pads. Front brake caliper The pad thickness must not be less than 1 mm. If the pads are excessively worn, substitute them.

  • Page 306: Substitution And Bleeding Of The Front Brake Fluid

    Brakes To effectuate the assembly of the new pads, align the holes of the pads with the holes in the caliper. After having visually checked the condition of the pad plates, check that they offer sufficient pressure to the pad during the assembly phase. Check the condition of the pad-retaining threaded pin.
  • Page 307 Brakes Repeatedly squeeze the front brake lever, then hold it continuing the braking action. Remove the protection cap of the bleed valve of the front right caliper. Apply a rubber tube to the bleed valve (the valve is pla- ced on the summit of the brake pincer). Put the other end of the rubber tube in a suitable con- tainer.
  • Page 308 Brakes Continue the operation for both calipers, proceeding as described previously. Pour new brake fluid into the chamber until it reaches the maximum level. Recommended brake fluid : A G I P B r a k e Fluid DOT 4 Utilise only the prescribed brake fluid from sealed containers.
  • Page 309 Brakes Top-up the level of the fluid until it reaches the maxi- mum mark. Carefully clean around the edge of the brake fluid chamber utilising a clean cloth. Imperfect cleaning of this component could cause the loss of small quantities of brake fluid whilst riding.

  • Page 310: Front Brake Calipers Substitution

    Brakes Place the cap on the brake fluid chamber and tighten the two lateral fixing screws. FRONT BRAKE CALIPERS SUBSTITUTION Pull the front brake lever as near as possible to the right handgrip maintaining it in position with an elastic band before starting the removal operation of the brake caliper.

  • Page 311: Front Brake Pump Removal

    Brakes FRONT BRAKE PUMP REMOVAL Empty the system of brake fluid as described in page Remove the union indicated in the figure. Brake fluid is extremely corrosive. Avoid contact with the yes, skin and nose. Wash abundantly with water and call a doc- tor if accidental contact occurs.

  • Page 312: Front Brake Lever Removal

    Brakes To substitute the front brake switch remove the screw shown in the figure. After having carried out the overhaul of the front brake pump assembly, carefully wash and bleed the front brake system as previou- sly described in this chapter. FRONT BRAKE LEVER REMOVAL Unscrew the fixing nut locking the pin rotation with a screwdriver.

  • Page 313: Clutch Lever Removal

    Brakes When reassembling take care to insert the lever into its seat. 8÷10 N•m Grease the pin: Recommended grease: Agip Grease 30 Insert the pin into the seat and screw it in until the beat is reached, then tighten the nut by using a screwdriver. Front brake lever nut torque pressure: 8 ÷...

  • Page 314: Front Brake Discs

    Brakes When reassembling, be careful to insert the pin of the pump piston into the seat situated on the lever (see figure). Grease the pin: Recommended grease: Agip Grease 30 For the reassembly of the lever tighten the pin. Keeping the pin still, tighten the nut with a screwdriver. Clutch lever nut torque pressure: 8 ÷...

  • Page 315: Front Brake Disc Removal Removal

    Brakes FRONT BRAKE DISC REMOVAL REMOVAL Remove the front wheel from the motorcycle (see paragraph “Front brake caliper removal”). Remove the front wheel pin utilising two special tools (see chapter F “Suspensions and wheels”). Special tool 800092872 Place the wheel in a horizontal position on a work plane and remove the five screws of each disc procee- ding in a star-like mode for the removal.
  • Page 316 Brakes Front disc assembly Thoroughly clean the contact surfaces of the discs and the wheel. Accurately grease all relative surfaces of the disc befo- re reassembling. The following operation must be carried out only on the following model: • Brutale S Apply thread-locking fluid to the five fixing screws of the disc.
  • Page 317 Brakes Screw in the screws lightly, proceeding in a star-like mode. 23÷25 N•m Continuing in a star-like mode, tighten the screws to the prescribed torque pressures. Front brake disc screw torque pressure: 23 ÷ 25 N•m Be careful to reassemble the discs in the original posi- tions (it is advisable to mark them by applying an adhe- sive label).

  • Page 318: Rear Brake System

    Brakes REAR BRAKE SYSTEM N•m 220 ÷ 240 15 ÷ 20 16 ÷ 18 16 ÷ 18 18 ÷ 20 5 ÷ 7 Torque Kg•m pressure ft•lb Operation Description BRUTALE ORO BRUTALE S REAR BRAKE Type Steel disc Ø disc (mm) Pincer (Ø...

  • Page 319: Rear Brake Pads Substitution

    Brakes REAR BRAKE PADS SUBSTITUTION Place the motorcycle on the rear stand. Special tool N. 800092642 Remove the fixing screws of the lower silencer. Remove the exhaust protection. Turn the lower silencer outwards slightly. If this movement is difficult due to residues in the area of connection to the compensator, clean the part applying lubricant / WD-40 unblocking spray.
  • Page 320 Brakes Remove the retaining ring of the wheel nut. Remove the rear wheel by removing the polygonal nut, using the following tools: Torque wrench 55 mm polygonal spanner Utilising a torque wrench, slacken the rear wheel nut. The polygonal fixing nut of the rear wheel has a left hand thread.
  • Page 321 Brakes Utilising circlip pincers as shown in the figure, widen the pads so that the pistons are pushed back into their seats. The outward movement of the brake pads provocates the retraction of the pistons in their relative seats, with a consequent increase in the level of the brake fluid in the brake fluid chamber.

  • Page 322: Substitution And Bleeding Of The Rear Brake Fluid

    Brakes Analyse the condition of the rear brake system and its components. Proceed with the reassembly in the reverse order of removal. Tighten the pin to the prescribed torque pressure. Rear brake caliper pin torque pressure: 15 ÷ 20 N•m 15÷20 N•m SUBSTITUTION AND BLEEDING OF THE REAR BRAKE FLUID...
  • Page 323 Brakes Open the cover of the rear brake fluid reservoir by removing the two screws. Be careful to not spill the fluid from the reservoir during these operations. Brake fluid is extremely corrosive. Avoid contract with the eyes, skin and nose. Wash abundantly with water if contact is accidentally made and consult a doctor.

  • Page 324: Rear Brake Caliper Substitution

    Brakes Tighten the bleed valve. Fill the rear brake fluid reservoir until the fluid reaches the maximum level. Recommended brake fluid : A G I P B r a k e Fluid DOT 4 Utilise exclusively the prescribed brake fluid. Use only new brake fluid from sealed containers.
  • Page 325 Brakes Assemble the union tightening to the prescribed tor- que. 16÷18 N•m Torque pressure: 16 ÷18 N•m Substitute the gaskets with new ones. N.B. If the brake pads have been removed, reassemble them. Proceed with the filling and bleeding of the rear brake system (see page 22).

  • Page 326: Rear Brake Disc

    Brakes Unscrew the two fixing screws of the brake pump to its relative support. Remove the pump. The figures show the collectors when N.B. removed, but the operation is still possible with the exhaust collectors assembled. After having carried out a check on all components and substituted those used, damaged or defective proceed 16÷18 N•m 8÷10 N•m...

  • Page 327: Rear Brake Disc Removal

    Brakes REAR BRAKE DISC REMOVAL Before proceeding with the removal of the rear brake disc, it is necessary to carry out certain operations described previously in this chapter: Remove the rear wheel. Remove the rear brake disc from its support. Remove the four nuts fixing the disc to the flange spli- ned to the wheel pin.
  • Page 328 Brakes Before reassembling the rear brake disc, check the condition of the four pins and four special nuts. 18÷20 N•m Proceed with tightening of the nuts. The screws must be assembled with the nuts screwed in lightly and brought into con- tact with the disc surface.

  • Page 329: Cooling System And Lubrication System

    Cooling system and lubrication system SECTION Revision 0 - 1 -...
  • Page 330 Cooling system and lubrication system SUMMARY COMPLETE COOLING SYSTEM ASSEMBLY AND LUBRICATION SYSTEM...........PAGE 3 COOLING SYSTEM LEAKAGE CHECK ....................PAGE 4 EXPANSION TANK CAP CHECK ......................PAGE 4 ENGINE COOLANT EXTRACTION......................PAGE 5 EXPANSION TANK REMOVAL .........................PAGE 5 DISASSEMBLING WATER RADIATOR ....................PAGE 8 DISASSEMBLING ELECTRIC FAN ......................PAGE 12 CHECKING COOLING FAN STARTER.....................PAGE 13 COOLANT TEMPERATURE SENSOR .....................PAGE 15...

  • Page 331: Complete Cooling System Assembly And Lubrication System

    Cooling system and lubrication system COMPLETE COOLING SYSTEM ASSEMBLY AND LUBRICATION SYSTEM Before checking, disposing of, or overhauling any component relevant to the cooling and lubrication perform some preliminary operations system: 1) Let the engine cool down. 2) Remove the passenger and pilot seat, right and left side panel, fuel tank and air filter compartment as descri- bed in the chapter C “Superstructures”.

  • Page 332: Cooling System Leakage Check

    Cooling system and lubrication system COOLING SYSTEM LEAKAGE CHECK Before removing the radiator and discharging the engi- ne coolant, check that the cooling system does not have leakages. Remove the expansion tank cap and connect the tester (of the type shown in the diagram) to the filler hole.

  • Page 333: Engine Coolant Extraction

    Cooling system and lubrication system ENGINE COOLANT EXTRACTION Remove the ignition commutator cover unscrewing the two fixing screws (1). Open the cap of the expansion tank (2). Empty the cooling system of the coolant as follows: • Place under the engine a container to collect the discharged coolant;...
  • Page 334 Cooling system and lubrication system Disconnect the connector (1) of the ignition switch and remove its rubber clamp (2) acting on the right side of the motorcycle. On the right side of the motorcycle remove the clamp (1) connecting water radiator breather pipe to the expansion tank using specific pliers CLIC R 205 and its rubber clamp (2).
  • Page 335 Cooling system and lubrication system In order to extract the pipe you should release it from the fixing point shown by the arrow in the figure on the side. Remove the ignition switch support unscrewing the four screws (1). On the left side of the motorcycle remove the clamp (1) connecting the water radiator charging pipe to the expansion tank using a specific pliers CLIC R 205 and its rubber clamp placed near the fluid supply tank.

  • Page 336: Disassembling Water Radiator

    Cooling system and lubrication system DISASSEMBLING WATER RADIATOR Remove the upper (1) and side (2) protections of the water radiator unscrewing the respective fixing screws on both sides of the radiator. Remove the oil radiator protection (1) unscrewing the two fixing screws. Remove the upper plastic protection (1) unscrewing the two fixing screws.
  • Page 337 Cooling system and lubrication system Remove the protective grid (1) taking it out from its seat. Disconnect the connector (1) of the water radiator elec- tric fan on the right side of the motorcycle. Disconnect the connector (1) of the water temperature sensor to the instrumentation panel on the left side of the motorcycle.
  • Page 338 Cooling system and lubrication system Remove the clamp (1) on the water suction pipe cou- pling from the pump to the radiator using the specific pliers CLIC R 205. Specific tool - pliers CLIC R 205 Remove the clamp (1) on the water inlet pipe coupling to the radiator from the thermostat valve using the spe- cific pliers CLIC R 205.
  • Page 339 Cooling system and lubrication system Move the radiator towards the front side of the motorcycle in order to the release the water suction pipe coupling (1) from the pump to the radiator. Release the water inlet pipe coupling to the radiator (1) to the radiator from the thermostat valve.

  • Page 340: Disassembling Electric Fan

    Cooling system and lubrication system Remove the radiator moving it right in order to release it from the peg (A) on the frame support. DISASSEMBLING ELECTRIC FAN Unscrew the three screws (1) and remove the comple- te fan support. For replacing fan you should remove the three nuts (1) for fixing fan (2) and protecting (3) the support (4).

  • Page 341: Checking Cooling Fan Starter

    Cooling system and lubrication system CHECKING COOLING FAN STARTER In order to verify the efficiency of the electric fan star- Ampmeter Motorino ter, this starter must be connected as shown in the figu- Fan motor elettroventola Amperometro re by using voltmeter and amperometer. During the test the starter must be powered.
  • Page 342 Cooling system and lubrication system Ensure that the protective sheath (2) is inserted on the fan wiring. Position the wiring of the upper electric cooling fan as indicated in the figure. Insert the electrical connector into its tongue support in the area indicated of the fan frame and fix the cable using the appropriate tear clamps (1) as shown in the figure.

  • Page 343: Coolant Temperature Sensor

    Cooling system and lubrication system COOLANT TEMPERATURE SENSOR If it is necessary to check the efficiency of the coolant temperature sensor, proceed as follows. Disconnect the electrical connector as shown in the figure. Remove the coolant temperature sensor. Checking water temperature sensor Check that the resistance of the coolant temperature sen- sor varies with the temperature as shown.

  • Page 344: Removing Thermostat Valve

    Cooling system and lubrication system Assembling water temperature sensor 18 N•m Before assembling the sensor, apply Teflon tape onto the threaded section of the sensor. Tighten the coolant temperature sensor to the speci- fied torque pressure. Coolant temperature sensor torque pressu- re: 18 N•m Be careful when inserting the coolant tem- perature sensor.
  • Page 345 Cooling system and lubrication system Remove the cover of the thermostat (1). Remove the thermostat (2). Checking thermostat valve Check to see if the thermostat pad is damaged. Check the functioning of the thermostat as follows: • Suspend the thermostat by a piece of string threa- ded through the flange as indicated in the figure.

  • Page 346: Reassembling Thermostat Valve

    Cooling system and lubrication system REASSEMBLING THERMOSTAT VALVE Insert the O-ring (1) in its appropriate seat on the cover of the thermostat. Check the condition of the O-ring previously utilised. If the O-ring is not in good condition, substi- tute it with a new one. Apply a thin layer of silicone grease.
  • Page 347 Cooling system and lubrication system Insert the cover of the thermostat, complete with ther- mostat onto the engine. 10 N•m Tighten the three fixing screws (1) to the prescribed torque pressure. Torque pressure: 10 N•m Tighten the H O sensor (1) for gearcase, ensuring that the connector is in horizontal or standing position.

  • Page 348: Reassembling Expansion Tank

    Cooling system and lubrication system REASSEMBLING EXPANSION TANK Position the tube in respect of the expansion tank as indicated in the figure. Position the expansion tank on the frame; if the opera- tion is difficult, slightly turn the tank clockwise. Insert the radiator water breather pipe (1) and the over- flow pipe (2) inside the seats on the plastic clip (3).
  • Page 349 Cooling system and lubrication system If the overflow pipe had been previously removed, see to put it again and fix it using the three rubber clamps (1) as shown in the figure. Ensure that the placement follows the figure and inclu- des also the clutch control piping (2).

  • Page 350: Assembling Water Radiator

    Cooling system and lubrication system On the left side of the motorcycle, insert the water radiator connecting pipe (2) to the expansion tank. Secure it using a clamp (1) CLIC R 205 with relevant specific pliers. Specific tool CLIC R 205 Reconnect the connector (1) with the main wiring con- nection.
  • Page 351 Cooling system and lubrication system On the left side of the motorcycle insert the radiator fixing screw and tighten it to the prescribed torque 10 N•m wrench. Torque wrench setting of the radiator fixing screw: 10 N•m Insert the delivery pipe coupling that connects the ther- mostat valve with the radiator.
  • Page 352 Cooling system and lubrication system On the right side of the motorcycle connect the electric fan connector (1) with the main wiring. Always on the right side of the motorcycle insert the breather pipe (1) on the radiator nozzle. Secure it using a clamp CLIC R 96 120 (black). Connect both the pipe and the electric fan wiring by using a rubber clamp (2).
  • Page 353 Cooling system and lubrication system Assemble the plastic upper protection (1) and secure it using the two fixing screws. Assemble the side (2) and upper (1) protections secu- ring them on the radiator using the respective fixing screws. Perform the same operation for assembling the oil radiator protection.
  • Page 354 Cooling system and lubrication system Fill the system using the appropriate fluid. Fill until the notch indicating the MIN level is reached. Tighten the sealing cap of the expansion tank. For assembling repeat the same phases described for disassembling the components, but reversing the order.

  • Page 355: Removing Oil Radiator

    Cooling system and lubrication system Verify the coolant level inside the expansion tank again. It must reach the line shown in the figure, keeping sli- ghtly over the MIN reference. If the level is lower than the line shown, reset it adding new liquid from the filling cap;...
  • Page 356 Cooling system and lubrication system Remove the filling cap (1) on the right side of the motorcycle in order to facilitate the oil spill. Wait for the complete draining of the lubrication system. Remove the oil radiator protection unscrewing the two fixing screws.
  • Page 357 Cooling system and lubrication system Release the junction spring (1) between compensator and manifold of cylinders 3 and 4. Remove the manifold of cylinders 3 and 4. Release the junction spring (1) between compensator and manifold of cylinders 1 and 2. Remove the manifold of cylinders 1 and 2.
  • Page 358 Cooling system and lubrication system Remove the engine/ radiator support fixing screw pla- ced on the left side. This figure and the next ones show an N.B. engine assembly which the water radiator has been removed from; but the described operations can be performed also when the radiator is assembled.

  • Page 359: Reassembling Oil Radiator

    Cooling system and lubrication system REASSEMBLING OIL RADIATOR Insert the support peg in the support (1) on the right side making the oil radiator move from left to right. Connect the engine/radiator anchor rod (1) on the left side. Put the radiator/engine support on the left side again and secure it tightening the screw.
  • Page 360 Cooling system and lubrication system If pipings and unions had been removed from the radiator, reassemble carefully. Lubricate 18 ÷ 20 N•m 18 ÷ 20 N•m the union threads using engine oil. Tighten pipings and unions to the prescribed torque wrench.
  • Page 361 Cooling system and lubrication system Refasten the junction springs (1) between compensa- tor and manifolds of cylinders 1-2-3-4. Reassemble the oil radiator protection securing it by the appropriate screws. Before reassembling the plug, verify the complete clea- ning and the good condition of the seal. On the oil drain plug there is a magnet for attracting any ferrous residuals which could form in the engine during the rotation.
  • Page 362 Cooling system and lubrication system Reset the correct oil level inside the engine, verifying from the appropriate port on the right side of the engi- After having reset the correct level, close the filling cap (1) again. Start the engine for some minutes. After having shut off the engine, wait for at least 10 minutes and check the oil level.

  • Page 363: Special Tools

    Special tools SECTION Revision 0 - 1 -...
  • Page 364 Special tools Maintenance tools The special tools shown in the following chapter are indispensable for a correct carrying out of the described maintenance operations. To order the special tools, refer to the spare parts catalogue. - 2 -...
  • Page 365 Special tools Code Q.ty Note BRUTALE ORO BRUTALE S Descrizione Description I FRAME I I ENGINE I 800092872 • • Chiave perno Front wheel ruota anteriore spindle spanner 800091645 • • Chiave ghiera Steering bearing cuscinetti di sterzo pin wrench 800092857 •...
  • Page 366 Special tools - 4 -...
  • Page 367 Special tools Code Q.ty Note BRUTALE ORO BRUTALE S Descrizione Description I FRAME I I ENGINE I 800092867 • • Attrezzo montaggio Equaliser pacco bilanciere pack tool 800092868 • • Attrezzo cuscinetti Front wheel ruota anteriore bearings tool 800095389 • •...
  • Page 368 Special tools - 6 -...
  • Page 369 Special tools Code Q.ty Note BRUTALE ORO BRUTALE S Descrizione Description I FRAME I I ENGINE I 800094792 • • Attrezzo montaggio Gear change cambio mounting tool 800086119 • • Bussola di Locating bush riferimento 800081424 • • Cuscinetto Bearing 800086121 •...
  • Page 370 Special tools - 8 -...
  • Page 371 Special tools Code Q.ty Note BRUTALE ORO BRUTALE S Descrizione Description I FRAME I I ENGINE I 8000A1874 • • Attrezzatura per Fuel tank sostegno serbatoio support benzina assembly 8000A0965 • • Supporto per Fuel tank serbatoio benzina support 8000A1876 •...
  • Page 372 Special tools - 10 -...

  • Page 373: Torque Pressures

    Torque pressures SECTION Revision 0 - 1 -...
  • Page 374 Torque pressures SUMMARY TORQUE PRESSURES – CYCLE PARTS, EXCLUDING ENGINE - BRUTALE S FRAME ..............................PAGE 3 HANDLEBARS AND CONTROLS ......................PAGE 3 FRONT SUSPENSION ..........................PAGE 3 REAR SUSPENSION ..........................PAGE 3 FAIRING AND MUDGUARDS ........................PAGE 3 ELECTRICAL SYSTEM ..........................PAGE 4 FUEL FEED..............................PAGE 4 WHEELS AND BRAKES ..........................PAGE 4 EXHAUST SYSTEM...........................PAGE 4 INSTRUMENTATION ..........................PAGE 4...
  • Page 375 Torque pressures - 3 -...
  • Page 376 Torque pressures - 4 -...

  • Page 377: Diagnostics

    Diagnostics SECTION Revision 0 - 1 -...

  • Page 378: Electrical Parts

    Diagnostics DIAGNOSTICS ELECTRICAL PARTS CHARGING SYSTEM Battery warning light on Defective alternator Substitute Defective alternator connection Check Defective battery Substitute Recharging fuse (40A) burnt out Substitute Defective recharging fuse connection Deoxidise/replace Oxidised battery connections Deoxidise/replace SERVICES ELECTRICAL SYSTEM 12V No function is operative Defective ignition switch Substitute Defective ignition switch connection...
  • Page 379 Diagnostics Horn does not function D4 fuse burnt out Substitute Defective D4 fuse connection Deoxidise/replace Defective klaxon Substitute Direction indicators do not function D4 fuse burnt out Substitute Defective D4 fuse connection Deoxidise/replace Defective intermittency Substitute Defective intermittency connection Deoxidise/replace Bulbs burnt out Substitute Defective bulb connection...
  • Page 380 Diagnostics INJECTION IGNITION IAW 1.6M Pressure sensor/air temperature signal error Defective sensor Substitute Defective sensor connection Deoxidise/replace Butterfly valve potentiometer signal error Defective potentiometer Substitute Defective potentiometer connection Deoxidise/replace Engine temperature sensor signal error Defective engine temperature sensor Substitute Defective engine temperature sensor connection Deoxidise/replace FUEL INJECTION SYSTEM Injector does not inject fuel...
  • Page 381 Diagnostics FRONT WHEEL Front wheel oscillates/vibrates Bent wheel rim Substitute Wheel not balanced Balance the wheel Defective tyre Substitute Non-recommended tyre Substitute Damaged wheel bearings Substitute Wheel fixing screws not tightened Tighten Wheel spindle fixing ring not tightened Tighten Front wheel does not turn easily Damaged bearings Substitute Bent wheel spindle...
  • Page 382 Diagnostics Insufficient braking power Discs dirty Clean Air bubbles in the braking system Bleed Leakages in the braking system Repair Damaged pincer seals Substitute Damaged pump seals Substitute Pincer pistons do not operate smoothly Check Low brake fluid level Top-up Deformed brake discs Substitute Brake pads brush against the discs...

  • Page 383: Analytical Index

    Analytical index SECTION Revision 0 - 1 -...
  • Page 384 Analytical index ANALYTICAL INDEX – BRUTALE WORKSHOP Rear wheel hub ......B-74 MANUAL Screws and nuts ......B-76 SIde stand .
  • Page 385 Analytical index Injection time (injection volume) ... .D-3 Starter motor check .....E-33 Injection time compensation .
  • Page 386 Analytical index Chapter H - Brakes Chapter M - Special tools CLutch lever removal ....H-13 Maintenance tools ..... .M-2 Front brake calipers substitution .

This manual is also suitable for:

F4 brutale 750 oro750 s910 s

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