Page 2 © 2012 The reproduction, even partial of this document is forbidden without prior written agreement of MV Agusta Motor S.p.A. Part no. 8A00B7594 - Edition no. 1 Printed – April 2012...
Page 3 Motorcycle workshop manual MV AGUSTA F3 675 - F3 SERIE ORO...
Page 4 Everything that we do has repercussions on the entire planet and its resources. Respect and defend the environment 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 5 Freni General Index GENERAL DESCRIPTION..................Rev. 0 MAINTENANCE ......................Rev. 0 BODYWORK ......................Rev. 0 AIR INTAKE INJECTION SYSTEM ................Rev. 0 ELECTRICAL SYSTEM .................... Rev. 0 SUSPENSION AND WHEELS .................. Rev. 0 FRAME ........................Rev. 0 BRAKES........................Rev. 0 COOLING SYSTEM ....................
Page 7 General description SECTION Revision 0 - 1 -...
Page 8 General description SUMMARY HOW TO CONSULT THIS MANUAL ........... . .PAGE 3 THE PURPOSE OF THIS MANUAL .
Page 9: How To Consult This Manual
All information, instructions and technical data included in this manual are based upon information on the prod- uct updated at the moment of going to print. MV Agusta Motor S.p.A. reserves the right to carry out changes at any moment without prior notice and without incurring any obligation.
Page 10: Glossary And Symbols
General description GLOSSARY AND SYMBOLS This signifies that the lack Use the recommended suspension fluid. ATTENTION incomplete obser vance of this advice can be gravely dangerous for your safety and for the safety of other persons. Use the recommended coolant. This signifies that the lack WARNING of observance of these...
Page 11: Right Hand And Left Hand Standard
General description RIGHT HAND AND LEFT HAND STANDARD To clarify the right hand and left hand standard that is used in this manual, herewith below is a diagram of the motorcycle and the engine against which are indicated the right and left sides. Cylinder 3 Cylinder 2 Cylinder 1...
Page 12: 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 13 • 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 14: Index
• Slackening or tightening nuts or screws, always start with those of a greater dimension or from the centre. Always respect the torque values indicated. • Utilise only MV Agusta spare parts. INDEX GENERAL INDEX SUMMARY OF EACH CHAPTER...
Page 15: Operative Technical Specifications
General description OPERATIVE TECHNICAL SPECIFICATIONS MOTORCYCLE IDENTIFICATION The registration number of the motorcycle is stamped on the right side of the steering head. The engine registration number is stamped on the upper engine casing, near the swingarm. 2) Engine registration number 1) Frame registration number 3) Homologation date Below is an example of the designation of the frame registration number:...
Page 16 General description - 10 -...
Page 17 Maintenance SECTION Revision 0 - 1 -...
Page 18 Maintenance SUMMARY TECHNICAL INFORMATION ............PAGE 3 PERIODICAL MAINTENANCE SCHEDULE .
Page 19: Technical Information
Maintenance TECHNICAL INFORMATION TECHNICAL DATA Description F3 675 F3 ORO Wheelbase (mm) (*) 1380 CHARACTERISTICS Total length (mm) (*) 2060 Maximum width (mm) Seat height (mm) (*) Ground clearance (mm) (*) Trail (mm) (*) Dry weight (kg) Fuel tank capacity (lt) (**)
Page 20: Technical Data
Maintenance TECHNICAL DATA Description F3 675 F3 ORO Type Double-overhead camshaft TIMING Type Wet sump LUBRICATION Type Eldor EM2.0 “NEMO” integrated ignition-injection system with Mikuni Motorised throttle body; IGNITION - FUEL FEED SYSTEM inductive discharge electronic ignition; “Multipoint” phased sequential electronic injection.
Page 21 Maintenance TECHNICAL DATA Description F3 675 F3 ORO Front 120/70 ZR 17 M/C (58 W) TYRES Rear 180/55 ZR 17 M/C (73 W) Brand and type PIRELLI - Diablo Rosso Corsa Tyre pressure (*) Front 2.3 bar (33 psi) Rear 2.3 bar (33 psi)
Page 22: Periodical Maintenance Schedule
We respect and defend the environment. 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 23 Maintenance Programmed maintenance schedule 1000 6000 12000 18000 24000 30000 36000 Km (mi) covered (600) (3800) (7500) (11200) (14900) (18600) (22400) Pre- Service delivery Description Operation Check / adjust Transmission and flexible controls ● ● ● ● ● ● ● ●...
Page 24: Table Of Lubricants/Fluids
D.I.D. CHAIN LUBE – * : To find the recommended product, MV Agusta suggests going directly to the authorised MV Agusta dealers. Eni i-Ride moto2 5W/40 has been manufactured for the F3 engine. If the described oil is not available, MV...
Page 25 Maintenance Place a container underneath the engine to collect the used oil. Remove the oil discharge plug (1). Recover the oil in an appropriate container. Do not scatter the drainage oil into the environment. Allow the lubrication system to drain completely. Remove the 4 fixing screws (2) of the oil filter cover.
Page 26 Maintenance Replace the oil filter and put the cover back on. Torque pressure for cover oil filter screws: 10 N·m 10 N•m On the oil discharge plug there is a magnet to attract any metal residues that could form in the engine during rotation.
Page 27: Engine Coolant
Maintenance Switch on the engine for several minutes. After switching off the engine, wait at least ten minutes and then check the oil level. Ensure that the motorcycle is placed on level ground and is in a vertical position. The level must be within the “MIN” and “MAX” refer- ences marked on the cap rod.
Page 28 Maintenance If the level is under the minimum line, proceed with top- ping-up as follows: With the engine cold, unscrew and remove the coolant filler cap (2). Using a syringe, top up with the recom- mended coolant on page B-8. Open the expansion tank only when the engine is cold;...
Page 29 Maintenance Engine coolant substitution Substitution→ every two years Before proceeding the emptying of the system, remove: the left under fairing; the left and right side fairing (see chapter C “Bodywork”); tail side panels; fuel tank; place a container under the engine to collect the used coolant;...
Page 30: Electric Cooling Fan
Maintenance Check once again the level of the coolant inside the expansion tank. This must reach a position above the "MIN" line marked on the expansion tank. If the level is inferior to the «MIN» mark, top up the coolant level by pouring new coolant into the filler hole. MIN level Complete the assembly of the motorcycle.
Page 31: Valve Mechanism Adjustment
Maintenance Check and adjust → at 1000 kilometres and then VALVE MECHANISM ADJUSTMENT every 12000 kilometres. Remove in order the following components to carry out the measuring of the play between the camshaft and the valve cups: • Under fairing •...
Page 32 Maintenance Remove the 3 screws (1) and the clamping bracket (2) for the plug-top coils. Take the 3 plug-top coils out, as shown in the figure. Clear the valve cover area (3). Systemise the HT leads, positioning them as indicated in the following figure.
Page 33 Maintenance Lift the front part of the motorcycle as shown in the fig- ure. Remove the 6 screws that hold down the cover of the engine head (4) starting from the centre as shown in the figure. Operating as shown in the figure, slightly lift up the cylinder head cover.
Page 34: Spark Plugs
Maintenance Timing chain, mobile timing chain guide and timing chain tensioner Check → Every 12000 kilometres Timing chain and mobile timing chain guide: Substitute → Every 36000 kilometres Check / substitute → Every 12000 kilometres Timing chain tensioner: To disassemble these parts and not being a part of nor- mal maintenance, it is necessary to proceed as described in the overhaul section of the F3 workshop engine manual (Part.
Page 35 Maintenance Check the heat grade of the spark plugs. Heat Grade Sparks: - NGK CR9 EKB DO NOT use non-resistive spark plugs. If appropriate (see Technical Data table), measure the Spark plug gap spark gap with a thickness metre. Adjust the gap if necessary on the basis of the following information: Sparks Spark plug gap...
Page 36: Fuel Filters
Maintenance Substitute → Every 50.000 km FUEL FILTERS For the substitution of the engine intake system filters (fuel filter, fuel pump filter), it is necessary to remove in sequence the following parts: • Saddle • Radiator side panels • Airbox side panels •...
Page 37 Maintenance Removing the fuel pump unit Lift the tank and proceed with the removal of the 6 screws (1) that hold down the retaining flange of the "Fuel pump" unit. Take the flange (2) out if its place. Using a screwdriver open the edge of the gasket and gently create leverage between the gasket and the flange until you feel the unit move.
Page 38 Maintenance Take the "Fuel pump" unit out by hand. Check the state of the sealing gasket (1) on the petrol Check and replace the gasket pump unit. Make sure that the gasket is perfectly intact and lubri- cate it by applying silicone grease. If it is damaged, change it for a new one.
Page 39 Maintenance Cut the 2 straps on the electric cabling (2) and (3). Disconnect the cabling (4) from the probe. Detach the unit by pulling from both sides. - 23 -...
Page 40 Maintenance Disconnect the cabling from the flange part by lifting the flaps and taking out the connector. Unweld the thermistor from the support bracket. Replace it with a new part and put it back in place by following the disassembly operations in reverse order. Remove the 2 self-tapping screws (1).
Page 41 Maintenance Cut the 2 straps on the electric cabling (2) and (3). Disconnect the cabling (4) from the probe. Detach the unit by pulling from both sides. - 25 -...
Page 42 Maintenance To remove the filter take off the strap (5) and slid the tube out (6). Take the O-ring (7) off of the front of the filter and slid the clamp off (8). Replace the filter with a new one. Insert the tube into the new filter and secure it with a new strap taken from the new supply kit, using the required tool.
Page 43: Fuel Pump Assembly
Maintenance FUEL PUMP ASSEMBLY - 27 -...
Page 44 Maintenance Position the fuel pump unit inside the fuel tank. Installing the fuel pump unit Be careful of the filter, positioning the electric connec- tor in a vertical position. Set the flange (1) up on the pump unit aligning it with the threaded holes on the tank.
Page 45: Tubes / Fuel Fittings
Maintenance Check for leaks ➝ First 1000 kilometres and then TUBES / FUEL FITTINGS every 6000 kilometres Carry out a visual check for eventual leakages from the fuel feed tubing and the unions (see figure). Substitute damaged parts if leaks or evaporation are found.
Page 46 Maintenance Lift the tank and disconnect the electrical connection to the pump unit (see chapter C Bodywork). Put the tank down and disconnect the main fuel tube from the pump by pressing the black ring nut down- wards. Put the new main fuel tube in the pump flange until it locks in.
Page 47 Maintenance Replacement the Rails fuel pipe connection Replacement ➝ At least every 3 year If the main Rails fuel pipe needs to be replace, the fol- lowing procedure must be carried out: Remove in the order: • Left under fairing •...
Page 48 Maintenance Disconnect the 3 injector connectors. Disconnect the air temperature sensor. Take down the Airbox (see procedure in chapter C "Bodywork"). - 32 -...
Page 49 Maintenance Disconnect the throttle body pipe from the Rails by pressing the two stop flaps and sliding the pipe off. Insert the new Rails connecting fuel pipe into the fitting installed on the throttle body, until you feel it is locked UTILISE ONLY NEW PARTS.
Page 50: Checking Engine During Idle
F3 675 – F3 ORO: Engine rpm 1400 ± 200 rpm Adaptive lambda check...
Page 51 Maintenance Check/substitute ➝ Every 6000 kilometres Air Filter Certain parts must be removed in sequence before acceding to the air filter. See chapter C “Bodywork”. • Left fairing side panel • Front fairing • Left air intake conduit cover • Left air intake conduit Remove the air filter (1) by sliding it out from the left airbox intake hole.
Page 52: Brakes
Maintenance BRAKES Check the levels of fluid in the systems➝ At pre-delivery, at first 1000 kilometres and then every 6000 kilometres. Check for leakages➝ At pre-delivery, at first 1000 kilometres and then every 6000 kilometres. Substitute fluid➝ Every 24000 kilometres or at least every two years.
Page 53 Maintenance Before completing the operation, clean and wash accu- rately with alcohol the three components of the fluid chamber cover and blow to dry them. Clean the edge of the fluid chamber with a clean cloth. Position the parts (4 and 5) on the tray. Screw the oil tank cap on and put the safety plate back on using the relative clamping screw.
Page 54 Maintenance No parts of the vehicle need to be removed from the Checking the level of the rear brake fluid vehicle to check the level of the rear brake fluid. If the fluid is below the low level mark, follow these steps to top up with brake fluid complying with the specifications: remove the oil tank (1) from the frame plate followed by...
Page 55 Maintenance place the tank with a strap and a protective cloth, securing it to the plate of the frame; The fluid in the braking circuit is highly cor- rosive. Avoid any contact with eyes, skin and mucous membranes. In case of accidental contact, wash thor- oughly with water and consult a doctor.
Page 56 Maintenance Before closing the tank make sure its parts are intact. Secure the rear brake fluid tank to the plate and then to the frame plate using Loctite with the required torque pressure: Torque pressure: 8 ÷ 10 N·m Apply Loctite Media 243 8÷10 N•m The substitution of the brake fluid and the successive Substitution and bleeding of the brake fluid...
Page 57: Brake / Gearchange Commands Check
Maintenance It is possible to adjust the position of the front brake BRAKE / GEARCHANGE COMMANDS CHECK lever and the rear brake and gear levers. Such adjust- ments have been created to optimise the grip and the movement of the commands with regards to the needs of the motorcyclist.
Page 58 Maintenance If the measurement differs by ±1 mm it is possible to act on the register located on the handlebar control. For greater differences set the register on the handle- bar at the indicated measurement of 22 mm. Adjust the main register sheltered by the clutch cover by acting on the two nuts, in order to restore the initial play of 3 mm measured on the lever.
Page 59 Maintenance Adjustment on the rear brake lever is carried out by Adjusting the rear brake lever F3 ORO acting on screw (1) which allows the pedal to turn 135°. To adjust the gear lever it is necessary to: Adjusting the gear lever 1) Remove guard (1) by removing the two screws (2).
Page 60 Maintenance 3) Screw/unscrew by hand the gearbox transmission rod 4 until the lever reaches the desired position. 4) Tighten the locknuts and the protection. The F3 ORO version, in addition to the adjustment of Adjustment of the gear change lever F3 ORO the version F3, also provides a 135* rotation for adjust- ing the pedal, achieved by rotating the screw 1 such as described for the rear brake lever.
Page 61: Brake Pads
Maintenance Rotate the footrest support in the desired position. Apply the recommended thread-locking fluid on the threads of the screw (1). Tighten the screw at the pre- scribed torque pressure. Thread-locking product used: Loctite 2400 Footrest support screw torque pressure: 40 N·m NOTE Adjust both footrests to the same position.
Page 62: Locks
Maintenance Check ➝ At the pre-delivery, at the first 1000 LOCKS kilometres and then every 6000 kilo- metres. Ignition/steering block switch This switch has three operating positions. Do not attach key rings or other objects to the ignition key that could obstruct the rota- tion of the steering.
Page 63 Maintenance Lift up the anti-dust cover. Fuel cap lock 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. Let the key go free, bring it into a longitudinal position and pull it out.
Page 64 Maintenance In order to reassemble the above mentioned part, you must perform the following operations: • Rotate the key into the lock • Press down the passenger seat • Release the key • Press down the seat once more, so to make sure of its firm coupling to the frame.
Page 65: Steering
Maintenance Check and adjust ➝ At the first 1000 kilometres STEERING 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”. Check ➝...
Page 66 Maintenance Regulation➝ At the first 1000 kilometres and then every 6000 kilometres. To adjust the chain tension, proceed as follows: Loosen the 2 rear wheel hub screws. 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 67 Maintenance Chain lubrication Lubricate➝ At the first 1000 kilometres and at 6000 kilometres and then at every 12000 kilometres. The chain is of the O-ring type. Clean the chain with a clean cloth and/or a jet of air. Apply the lubricant after cleaning. Utilise only the recommended lubricants or the equivalent (see page B-8).
Page 68: Tyres
Maintenance Check pressures➝ At the pre-delivery, at the first TYRES 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 69: Wheels
Maintenance Visual check ➝ At the first 1000 kilometres and WHEELS 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 planari- ty, the eccentricity and the ovalisation of the wheel. See the control procedures described in chapter F “Suspension and wheels”.
Page 70: Rear Shock Absorber
Carry out a check on the length of the rear shock absorber spring; check for leakages and trickles of oil and also check the adjustment function. Spring adjustment standard A: - F3 675: A = 161,5 mm - F3 ORO: A = 142 mm The shock absorber contains gas under high pressure.
Page 71: Side Stand
Maintenance SIDE STAND Functional check ➝ At the pre-delivery, first 1000 kilometres and then every 6000 kilometres. Make sure the bike cannot be started when the stand is down and the bike is in gear. Also check that with the engine switched on, when the side stand is lowered and a gear is engaged, the engine switches off auto- matically.
Page 72 Substitute oil ➝ every 24000 kilometres FRONT FORK F3 675 The front fork is vitally important for the handling and stability of the motorcycle. It is therefore necessary to substitute the fork oil at the prescribed intervals. To substitute the fork oil and to do a complete overhaul...
Page 73: Electrical System
Maintenance Check and tighten ➝ At the pre-delivery, at the first 1000 kilometres and then every 6000 kilometres. SCREWS AND NUTS Carry out an accurate check of the tightness of the nuts and screws on the motorcycle at the intervals prescribed. Consult the table in chapter N “Torque pressures”...
Page 74 Maintenance Multifunction display It displays the currently engaged gear. “N” stands 10 Gear display for “neutral”. Indicates the number of the control unit mapping cur- 11 Control unit mapping display rently selected. It displays the speed of the motorbike. It can be given 12 Speedometer in kilometres per hour (Km/h) or in miles per hour (Mph).
Page 75 Maintenance Some of the main measurements of the instruments Selecting and setting the display functions may be changed. The available options include: - Select an operating mode: “RUN” (Odometer) “SPEED LIMITER” “TC” (Traction control) “CHRONO” (Chronometer) “QUICK SHIFT” * “CLOCK” (Clock) - Reset the trip counter: Trip counter 1 “TRIP 1”...
Page 76 Maintenance In addition to the speedometer, the display shows the “RUN” mode following functions: • Total odometer “TOTAL” • Trip counter 1 “TRIP 1” As an alternative: • Total odometer “TOTAL” • Trip counter 2 “TRIP 2” “SPEED LIMITER” mode This mode adjusts the maximum value of the vehicle speed to your driving requirements.
Page 77 Maintenance This mode turns on the Chronometer and saves the “CHRONO” Mode recorded information. The following is displayed: • Chronometer Current lap “CURRENT LAP” • Chronometer Fastest lap “BEST LAP” • Chronometer Last lap “LAST LAP” • Rev counter Total laps covered “N° LAP” “QUICK SHIFT”...
Page 78 Maintenance To reset “TRIP 1” and “TRIP 2”, proceed as follows. Trip reset WARNING The display modes may be changed or set when the engine is off, the gear in neutral, the motorbike stationary with your feet on the ground. The display may not be changed while driving.
Page 79 Maintenance - By pressing the “OK” key for more than three sec- onds, the “TRIP 2” value will be reset to zero. When starting the engine, the “SPEED LIMITER” func- “SPEED LIMITER” mode tion is disabled. In order to activate it, it is necessary to perform the following operations: - Press “SET”...
Page 80 Maintenance - Press “OK” for over three seconds to confirm the selected maximum speed value. The displayed digit stops blinking and the display returns to “RUN” mode. - On the other hand, if you press “SET” for over three seconds, the “SPEED LIMITER” function is disabled. The display shows the “OFF”...
Page 81 Maintenance - Press “OK” for less than three seconds: the traction control level rises up to the next value. On the other hand, by pressing “SET” for less than three seconds, the traction control level decreases to the lower value. Such value may range between 0 and 8.
Page 82 Maintenance - Press the headlight button again to record the time taken to cover the 1st lap. At the same time, the instrument starts recording the time taken to cover the second lap. The time measurement for the first lap is stored in the memory and is visualised on the display for ten sec- onds, after which the time measurement for the follow- ing lap appears.
Page 83 Maintenance - Press “OK” for less than three seconds until “LAPS VIEW” appears. - By repeatedly pressing the key of the flashing high beam headlight, all the times previously acquired starting from the last lap memorised can be displayed in sequence. - Once all the data have been displayed, press the “SET”...
Page 84 Maintenance How to delete data To delete the saved data, proceed as follows: WARNING The display modes may be changed or set when the engine is off, the gear in neutral, the motorbike stationary with your feet on the ground. Do not change the display while driving.
Page 85 Maintenance - Subsequently, by pressing the flashing high beam headlight key followed by the “OK” key for more than three seconds, all the previously acquired times can be cancelled. - Once all the data have been cancelled, press the “SET” key to return to the “SINGLE LAP RESET” mode and then to the following mode.
Page 86 Maintenance - Now, press “OK” for over three seconds to delete the value. Otherwise, press “SET” for less than three sec- onds to stop the deletion procedure. - Once all the data have been cancelled, press the “SET” key to exit the “BEST LAP RESET” mode and then pass to the following mode.
Page 87 Maintenance - By pressing the “OK” key for more than three sec- onds, all the previously acquired times will be can- celled. By pressing the “SET” key for less than three seconds, the cancellation procedure will be interrupt- - Once all the data have been cancelled, press the “SET”...
Page 88 Maintenance Clock settings - To carry out clock settings, press the "SET" button until viewing the "CLOCK SETTING" caption. WARNING The display modes may be changed or set when the engine is off, the gear in neutral, the motorbike stationary with your feet on the ground.
Page 89 Maintenance How to select the mapping of the control unit On the F3 model is it possible to select different control unit mappings which allow to obtain variable power and performance characteristics based on the type of vehicle use. NOTE The mapping selection may be performed even during the use of the vehicle.
Page 90 Maintenance - Press “SET” until “SETTING C MAP” appears. In order to adjust the “Custom” mapping parameters to your driving requirements, perform the following oper- ations. - Throttle control sensitivity: Press “OK” for less than three seconds until “GAS SENSITIVITY” appears. - Press “SET”...
Page 91 Maintenance - Press “OK” for more than three seconds; the new set- ting will be confirmed. The displayed caption stops “GAS SENSITIVITY” mode. It is now possible to pro- flashing and after a few seconds the display returns to ceed with the setting of the following parameter. - Maximum engine torque: Press “OK”...
Page 92 Maintenance - Press “OK” for less than three seconds; the displayed setting will start flashing. - By repeatedly pressing “OK” for less than three sec- onds, the following settings can be displayed in • “RAIN” sequence: • “SPORT” - Press “OK” for more than three seconds; the new set- ting will be confirmed.
Page 93 Maintenance - Press “SET” for less than three seconds. The display shows the current setting for engine brake. - Press “OK” for less than three seconds; the displayed setting will start flashing. - By repeatedly pressing “OK” for less than three sec- onds, the following settings can be displayed in •...
Page 94 Maintenance - Engine response: Press “OK” for less than three sec- onds until “ENGINE RESPONSE” appears. - Press “SET” for less than three seconds. The display shows the current setting for engine response. - Press “OK” for less than three seconds; the displayed setting will start flashing.
Page 95 Maintenance - Press “OK” for more than three seconds; the new set- ting will be confirmed. The displayed caption stops “ENGINE RESPONSE” mode. flashing and after a few seconds the display returns to - Engine RPM limiter: Press “OK” for less than three seconds until “RPM LIMITER”...
Page 96 Maintenance - Press “OK” for less than three seconds; the displayed setting will start flashing. - By repeatedly pressing “OK” for less than three sec- onds, the following settings can be displayed in • “NORMAL” sequence: • “SPORT” - Press “OK” for more than three seconds; the new set- ting will be confirmed.
Page 97 Maintenance Warning/malfunction alerts The dashboard may highlight the presence of a fault or a malfunction during different using conditions of the motorcycle. - Engine start: As you turn the ignition switch to the ON position, the instruments and the warning lights will go through the self-diagnostic cycle.
Page 98 Maintenance - After the vehicle is stopped, the display shows the warning message highlighting the vehicle part or device on which the fault has been detected. - High coolant temperature: If a high value of the coolant temperature is detected, the display shows the warning alert shown in the picture.
Page 99 Maintenance “SERVICE” Mode This operating mode displays the mileage range with respect to expiration of the next scheduled mainte- nance. When the mileage range upon maintenance servicing NOTE is less than 1000 km, its relative value automatically appears after the start-up screen of the motorcycle. “UNIT CHANGE”...
Page 100 Maintenance - Press the "OK " button for less than three seconds until the message "SERVICE" is displayed. The mileage range with respect to expiration of the next scheduled maintenance is shown on this screen. - Mileage range resetting: After performing scheduled maintenance, the mileage range must be reset using the following procedure.
Page 101 Maintenance Changing the unit of measurement Allows for simultaneous editing of the following units of measure: • Speed • Distance covered WARNING The modification or adjustment of display functions must be carried out with the engine off and running on neutral, with the motorcycle stopped with the stands on the ground.
Page 102: Lights
Maintenance - Press the "OK " button for more than three seconds and the new unit of measurement configuration will be confirmed. The display returns to the "RUN" mode. Check ➝ At the pre-delivery, at the first 1000 LIGHTS kilometres and then every 6000 kilo- metres.
Page 103 Maintenance - Detach the connector. - Release the retaining spring. - Extract the bulb. CAUTION - Do not touch the bulb glass with bare hands. If you do, clean the bulb with an oil-free solvent. - Insert the new bulb. - Reattach the spring.
Page 104 Maintenance Replacing the front turn indicator bulbs - Remove the fixing screw. - Remove the lens. - To remove the burnt-out bulb, press it and rotate it counterclockwise. - 88 -...
Page 105 Maintenance - To fit the new bulb, press it and rotate it clockwise. - Refit the lens and tighten the fixing screw. Replacing the rear turn indicator bulbs - Remove the fixing screw. - Remove the lens. - Extract the bulb-holder and press the terminal ends of the bulb.
Page 106 Maintenance - To remove the burnt-out bulb, press it and rotate it counterclockwise. - To fit the new bulb, press it and rotate it clockwise. - Replace the bulb-holder. - Replace the lens and insert the fixing screw. Replacing the license plate light bulb - Remove the rear reflector, removing its fixing nuts.
Page 107 Maintenance - Remove the fixing nuts of the plate holder. - Remove the plate holder. - Extract the bulb holder pulling it from its seat. - Extract the burnt-out bulb. - Fit the new bulb. - Replace the bulb holder. - Replace the plate holder and the rear reflector.
Page 108 Maintenance Replacing the tail light bulb - Remove the two fixing screws of the rear tail plate. - Remove the fixing bracket of the rear plate. - Disengage and remove the rear tail plate. - Remove the four upper fixing screws of the tail side fairings.
Page 109 Maintenance - Detach the tail lamp connector. - Slightly open the tail side fairings and remove the tail lamp. - Extract the bulb holder pulling it from its seat. - Extract the burnt-out bulb. - Fit the new bulb. - Replace the bulb holder. - Reassemble the tail lamp and all the previously removed parts.
Page 110 Maintenance Replacing the brake light bulb - Remove the tail lamp as described previously. - To extract the bulb holder, rotate it counterclockwise. - Extract the burnt-out bulb. - Fit the new bulb. - Replace the bulb holder by rotating it clockwise. - Reassemble the tail lamp and all the previously removed parts.
Page 111: Fuses
Maintenance FUSES - The battery recharge fuse is located on the solenoid starter of the motorcycle. To expose it, remove the right side fairing of the motorcycle. Solenoid starter CAUTION Turn the ignition key on the “OFF” position before checking or replacing the fuses, in Spare fuse (30 A) order to avoid a short circuit with subse- quent damage to other electric parts of the...
Page 112 Maintenance - The service fuses are located on the right side of the motorcycle. - Release the two clamps and lift the fuse box cover. CAUTION Turn the ignition key on the “OFF” position before checking or replacing the fuses, in order to avoid a short circuit with subse- quent damage to other electric parts of the motorcycle.
Page 113 Maintenance - To identify the position and function of the fuses, refer to the information shown in the enclosed electrical diagram. The reference letters in the figure corre- spond to those shown in the diagram. Remember that the fuse box contains three spare fuses.
Page 114 Maintenance Check adjustment ➝ At every variation of the motorcycle set-up. FRONT HEADLAMP The headlight should be adjusted every time the geometry of the vehicle is altered and before carrying a pillion passenger. The motorcycle is not equipped with external adjusters and the front projector unit is fixed to the frame. Headlight adjustment Place the vehicle at a distance of 10 m from a vertical wall.
Page 115 Bodywork SECTION Revision 0 - 1 -...
Page 116 Bodywork SUMMARY FAIRING ASSEMBLY ............. . .PAGE 3 TAIL UNIT AND HEAT SHIELD .
Page 117 Bodywork FAIRING ASSEMBLY Right side Left side • This exploded view demonstrates the position of the bodywork and the method of disassembly and assembly. - 3 -...
Page 118 Bodywork Under-engine fairing removal Proceed to remove the four clamping items of the right under-fairing located respectively: - two screws (1) on the top side part; NOTE: do not remove the third screw (2) on the rear part. - Two screws (3) in the bottom part (1 rear and 1 front); Repeat the operation on the corresponding clamping items of the left under-fairing.
Page 119 Bodywork Unhook the pin (2) clamped to the frame. Remove the fairing side panel, sliding it off from the front side. Repeat the operation for the left fairing side panel. To separate the air manifold from the side panels, removing the four fixing screws (3). - 5 -...
Page 120 Bodywork Remove the two screws (1) that clamp the light onto Front fairing removal the low beam support on both sides using a 5 mm ball head hex screwdriver. Remove the two fixing screws (2) of the headlight fair- ing to the instrument panel support. Remove the four screws (3), two per side, that fasten the front cowl to the air ducts covers.
Page 121: Front Headlight
Bodywork Remove the two fixing screws (4) of the right rear-view mirror. Remove the connector (5) and take off the right rear- view mirror. Repeat operations for the left mirror. Remove the headlight fairing, sliding it toward the front part. The headlight will remain fastened to the fairing. Slide the front headlight connector (6) out by unscrew- ing it counter-clockwise.
Page 122 Bodywork TAIL UNIT AND HEAT SHIELD - 8 -...
Page 123 Bodywork Tail unit removal and heat shield Insert the ignition key into the seat lock. Press lightly on the rear part of the passenger seat as shown in the figure. Turn the key and unlock the seat. Lift up the passenger seat. Unscrew the screw (1) counter-clockwise and slide the driver's seat forwards.
Page 124 Bodywork Remove the tank side fairings (1) on both sides, unhooking it from the pin and sliding it toward the front part of the motorcycle (page C-13). Remove the right and left under seat side fairings removing the 12 screws (2). - 10 -...
Page 125 Bodywork Remove the side fairing toward the outside. Turn and slide the heat shield towards the rear part that has been freed up by taking down the underseat panels. - 11 -...
Page 126 Bodywork FUEL TANK AND AIR INTAKE DUCTS - 12 -...
Page 127 Bodywork Side fairing removal Extract the left and right side fairing support (1) as indi- cated in the figure. Unhook the rear part of the panel (A) from the clamp- ing pin, then remove it by sliding it (B) towards the front of the vehicle.
Page 128 Bodywork Remove the two side screws (3) that clamp the trian- gular plate to the frame on both sides. Free up the tank vent pipe by opening the three (4) rub- ber clamps. Disconnect the petrol pipe (5) from the three-way con- nector on the left side or the motorcycle.
Page 129 Bodywork Disconnect the petrol pump by disconnecting the 5- way electric connector (6). Lift up the fuel tank. While lifting the tank take care not to dam- age the airbox. Disassemble the duct cover panels Remove the two connecting screws (1) of the left panel (2) of the frame.
Page 130 Bodywork Lift the panel and unhook it from the two pins. Remove it outward. Repeat operations for the left panel. Unhook the snap fastener on the left line that clamps down the electric cable (3) of the left direction indica- tor.
Page 131 Bodywork Left and right air intake conduit removal Remove the six screws (1) that fasten the air lines to the airbox (three per side). At this point you must remove the right and left suction lines (2) by making them come out from the top part first.
Page 132 Bodywork AIR INTAKE SYSTEM - 18 -...
Page 133 Bodywork Airbox removal Remove the 9 fixing screws (1) of the airbox cover. Unhook the top petrol injection pipe (2) by pressing the coloured button on the connector. Remove the snap fastener (3) and then disconnect the electric connector (4) - 19 -...
Page 134 Bodywork Disconnect the air temperature sensor connector (1). Lift and remove the air box cover. Pull the ECU unit rubber mounting (2) out upwards from the battery housing. - 20 -...
Page 135 Bodywork Unhook the 2 ECU unit connectors (3) by pushing the button and turning the bayonet connector. Remove the air filter (4). Unhook the oil vapour tube. - 21 -...
Page 136 Bodywork Remove the two internal screws (5) that hold the air box to the valve cover. Lift and remove the airbox. - 22 -...
Page 137 Bodywork MUDGUARD - CENTRAL CONVEYOR - RADIATOR PROTECTION Right side Left side - 23 -...
Page 138 Bodywork Central manifold disassembly Slide off the two horn fastons (1). Remove the two clamping screws (2) and take out the central conveyor (3) removing the claxon as well (5). Front mudguard disassembly Unscrew and remove the 4 fixing screws (1) on the mudguard (2 per side).
Page 139 Bodywork Release the brake pipes from the three clamps (2), two on the right side and one on the left side. Slide the mudguard off of the front being careful of the pipe gland clamps. - 25 -...
Page 140 Bodywork Oil radiator protection disassembly The two halves of the oil radiator guard are removed from the motorcycle when the fairing side panels are taken off of the motorcycle. To remove the rh radiator guard from the fairing side panel, do the following: - Remove the two screws (1) that secure the rh guard.
Page 141 Air intake injection system SECTION Revision 0 - 1 -...
Page 142 Air intake injection system SUMMARY INJECTION SYSTEM TECHNICAL CHARACTERISTICS ........PAGE 3 INJECTION TIME COMPENSATION (VOLUME) .
Page 143 Air intake injection system INJECTION SYSTEM TECHNICAL CHARACTERISTICS The factors for the determination of the injection time are the basic injection time that is calculated on the basis INJECTION TIME (INJECTION VOLUME) of the r.p.m., the pressure of the intake duct and various compensations that are determined according to signals coming from various sensors that reveal the condition of the engine and the riding conditions.
Page 144 Air intake injection system INJECTION TIME COMPENSATION (VOLUME) The various sensors allow the injection time (volume) compensations to be carried out on the basis of the fol- lowing signals. SIGNAL DESCRIPTION When the atmospheric pressure is low, the sensor sends a signal to the ECU to reduce the injection ATMOSPHERIC PRESSURE SENSOR SIGNAL time (volume).
Page 145 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) and the regulator of the pressure. The fuel in the tank is pumped into the feed tubing at a controlled pressure by the rel- ative regulator and maintained at a certain constant value higher than the suction generated by the motor.
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 3,5 kg/cm (350 kPa).
Page 147 Air intake injection system When the ignition switch is turned to the ON position, the fuel pump motor is started by the current supplied by FUEL PUMP CONTROL SYSTEM the battery. 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 148 Air intake injection system The ECU is situated under the tank behind the battery. The ECU consists of a CPU (Central Processing Unit), a memory unit and I/O sections (input/output). The signal of each individual sensor is sent to the input section and then to the CPU.
Page 149 Air intake injection system The temperature of the intake air is found by con- 2 INTAKE AIR TEMPERATURE SENSOR verting the resistance of the Thermistor into voltage and then sending it to the ECU. The volume of the injection increases when the air temperature is low. The resistance of the Thermistor increases when the air temperature is low and diminishes when the tem- perature is high.
Page 150 Air intake injection system THROTTLE BODY POSITION SENSORS The throttle position sensors are inside the motor of the throttle body (1). These sensors are potentiometers with a variable resistance based on the opening angle of the acceler- ator and operate in a crossed fashion. The sensors are powered by the ECU at the estab- lished voltage of 5V and provide, in output, a voltage proportional to the throttle angle.
Page 151 Air intake injection system INJECTOR CHECK To check the injectors proceed as follows: - Disconnect the connector on each injector. - Proceed with checking the reel of each injector - The contact must not be open between the two pins of the injector, also, the resistance value must be 11 Ohm ±10% at 20°C.
Page 152 Air intake injection system - If the fuel pump unit does not continue to function correctly after the above-described tests, proceed with relative relay control (1) on the right side of the motorcycle, identified by a ring marked with "I" locat- ed on the cable bundle.
Page 153 Air intake injection system ACTUATORS The fuel injector consists of a solenoid, piston, needle valve and a filter. Fuel injector The injector is a small electromagnetic injection nozzle that injects fuel into the carburettor according to the sig- nal coming from the ECU. When the solenoid is agitated by the ECU, it becomes an electromagnet and attracts the piston.
Page 154 Air intake injection system DIAGNOSTICS SYSTEM For the diagnosis of the ignition and injection system a Ignition and injection system diagnostics TEXA diagnostic software is available which is capable of identifying and recording the faults present or that were present previously on the motorcycle. This soft- ware is equipped with a guide book for the use of the software itself to carry out checks on each individual component of the system.
Page 155 Air intake injection system AIR INTAKE SYSTEM TECHNICAL CHARACTERISTICS This motorcycle utilises direct induction in the air intake system. The frontal pressure of the air during normal rid- ing conditions is conducted to the air filter compartment in such a way that the incoming air is pressurised there- by improving the air intake efficiency to obtain greater power from the engine.
Page 156 Air intake injection system POSITIONS OF ENGINE-CONTROL SYSTEM PARTS - 16 -...
Page 157 Air intake injection system INJECTION SYSTEM ELECTRICAL DIAGRAM BATTERY FUEL PUMP, INJECTOR FUSE COIL FUSE FUEL PUMP - COILS - INJECTORS RELAY MAIN RELAY CLUTCH SWITCH THROTTLE BODY UPPER INJECTORS - 17 -...
Page 158 Air intake injection system Engine control unit pinout, MV Agusta F3 Connector Vehicle Engine Pin name Description of associated function Type IN_REL+ INPUT CRANKSHAFT POSITION SENSOR + VRS interface Pin n° Pin n° IN_REL- INPUT CRANKSHAFT POSITION SENSOR - VRS interface...
Page 159 Air intake injection system Engine control unit pinout, MV Agusta F3 Connector Vehicle Engine Pin name Description of associated function Type OUT_LOW_BEAM OUTPUT LOW BEAM LIGHT RELAY MANAGEMENT CONTROL Low side Pin n° Pin n° OUT_FAN_RELAY_1 OUTPUT ELECTRIC FAN RELAY MANAGEMENT CONTROL 1...
Page 160 Air intake injection system - 20 -...
Page 161 Electrical system SECTION Revision 0 - 1 -...
Page 162 Electrical system SUMMARY CONNECTORS ............................PAGE 3 COUPLINGS ............................PAGE 3 FUSES..............................PAGE 3 SEMICONDUCTOR PARTS ........................PAGE 4 ELECTRICAL DIAGRAM F3 675 - F3 ORO ...................PAGE 5 PARTS LIST ............................PAGE 6 BATTERY ..............................PAGE 7 CHARGING THE BATTERY ........................PAGE 8 REMOVAL OF THE BATTERY......................PAGE 9 RECHARGING SYSTEM........................PAGE 10 EFFICIENCY CHECK ...........................PAGE 12...
Page 163 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 CLICK COUPLINGS • Block couplings – ensure that the block is released before disconnecting it to push it completely home when connecting it.
Page 164 Electrical system SEMICONDUCTOR PARTS • Do not drop semiconductor parts such as those INCORRECT incorporated in the ECU. • When checking these parts, carry out the instruc- tions to the letter. The lack of using the correct pro- cedure can cause grave damage. - 4 -...
Page 165 Electrical system ELECTRICAL DIAGRAM F3 675 - F3 ORO - 5 -...
Page 166 Electrical system Parts list Parts list Ref. Description Ref. Description Rear stop switch Ignition switch Number plate light Right indicator Safety and Front stop switch Left indicator Right indicator Diagnostic connector (5A-serial line Front headlight RX; 5B-Ground; 5C-serial line TX) Instrument panel Main relay Air pressure sensor...
Page 167 Electrical system BATTERY The battery mounted on this motorcycle is a sealed battery therefore no maintenance is required. The following battery is used: KOYO KTZ-10S This is a sealed battery with breather valve. No elec- trolyte level checking is required. Never remove the battery seal caps nor block the breather opening.
Page 168: Charging Battery
Electrical system CHARGING THE BATTERY The battery is charged by connecting the supplied bat- tery charger to the connector located under the pas- senger seat. If the battery is charged after a period of vehicle downtime, make sure that the charger fuse is placed inside its housing on the remote ignition switch.
Page 169: Removal Of Battery
Electrical system REMOVAL OF THE BATTERY To carry out this operation it is necessary to remove the rear cowl, the sides and the tank as described in sec. C (Bodyworks). 1) Remove the negative pole (-) cable screw first. 2) Remove the positive pole (+) cable screw first. 3) Remove the battery by lifting it from its housing.
Page 170 Electrical system • Check the voltage charge after about thirty minutes at the battery terminals. Voltage > 12,5 Volt. CHARGING SYSTEM Warning function Conditions of abnormal operation of the battery charg- ing function (voltage 10V) is indicated by the warning lamp and the voltage value displayed on the dash- ≥...
Page 171 Electrical system A list of possible problems that could occur when the warning light is switched on. RESTORE OR CLEAN CON- WARNING LIGHT STILL ON PROBLEMS OCCUR NECTION WITH CONNECTION SI RISCONTRANO PROBLEMI RIPRISTINARE O PULIRE LA SPIA ANCORA ACCESA POSITIVE ON BATTERY SULLA CONNESSIONE CONNESSIONE...
Page 172 Electrical system BATTERY EFFICIENCY CHECK Battery current loss check • Remove the seats 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 173 Electrical system Measure the DC voltage between the positive (+) and the negative (-) terminals of the battery with a multi- tester. If the tester indicates less than 12.6V or more than 14.5V the cause will be found in the generator. NOTE When carrying out this check, ensure that the battery is fully charged.
Page 174 Electrical system BATTERY FUEL PUMP, INJECTOR FUSE COIL FUSE FUEL PUMP - COILS - INJECTORS RELAY MAIN RELAY CLUTCH SWITCH THROTTLE BODY UPPER INJECTORS - 14 -...
Page 175 Electrical system BATTERY FUEL PUMP, INJECTOR FUSE COIL FUSE FUEL PUMP - COILS - INJECTORS RELAY MAIN RELAY CLUTCH SWITCH THROTTLE BODY UPPER INJECTORS - 15 -...
Page 176 Electrical system BATTERY FUEL PUMP, INJECTOR FUSE COIL FUSE FUEL PUMP - COILS - INJECTORS RELAY MAIN RELAY CLUTCH SWITCH THROTTLE BODY UPPER INJECTORS - 16 -...
Page 177 Electrical system CHECKING THE GENERATOR • Disconnect the generator connector. • Make sure that there is a resistance of 0.3 Ohm ±10% at 20°C between each of the contacts of the 3 pins (generator line). • Make sure that there is NO continuity between each of the 3 pins and the engine earth.
Page 178 Electrical system • Remove the fuel tank (see chapter C “Bodywork”). STARTER MOTOR REMOVAL • Remove the battery mounting by unscrewing the three clamping screws (1). • Remove the seat lock plate. • Remove the blow-by tube. • Disconnect the cable of the starter motor. •...
Page 179 Electrical system If a fault has been diagnosed in the starter motor, it is STARTER MOTOR CHECK 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 180 Electrical system • Disconnect the cables of the starter motor and the positive cable of the battery from the relay. 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.
Page 181 Electrical system GEARCHANGE POSITION SWITCH The connector (1) of the gear position sensor is locat- ed on the left beneath the tank. Disconnect the connector of the gear position switch and check the resistance value, using a multitester, in the six gears as well as the idle position, as shown in the attached table.
Page 182: Fuses
Electrical system The fuses are situated on the right side of the motor- FUSES cycle. Remove the right side fairing. Lift the rubber cover. The fuses for the services are numbered from 1 to 7 starting from the left; there are three spare fuses on the part underneath.
Page 183 Electrical system SPARK PLUGS Remove the components of the motorcycle to remove the spark plugs as described in chapter B “Mainte- nance”. Remove the spark plugs utilising the appropriate 16mm hexagonal spark plug spanner. Check the resistance between the electrode and the screw cap of the spark plug as shown in the figure.
Page 184 Electrical system MAIN RELAY The main relay relay is on the right side of the battery compartment and it is identified by the “M” letter. To operate the relays conveniently it is necessary to remove the battery and its mounting. Take the general relay out (M) from the connector and check that there is a resistance of 82 Ohm ±10% at 20°C between pins 1 and 3.
Page 185 Electrical system ENGINE PICK-UP The engine pick-up 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 left side of the motor- cycle.
Page 186 Electrical system TIMING WHEEL GAP To guarantee the correct functioning of the pick-up it is necessary to measure the gap between the pick-up and the timing wheel by utilising a feeler gauge as shown in the figure. Gap width: 0.6 – 0.7 mm To carry out this check it is necessary to remove the cover of the timing wheel by consulting the Workshop Engine Manual.
Page 187 Electrical system Remove the connector holding device. With the switch in the RUN position make sure there is continuity between the Y/R (yellow/red) and Y/W (yel- low/white) wires. Holding the START button down, make sure there is continuity between the Y (yellow) and W/R (white/red) wires.
Page 188 Electrical system Consult the diagram below to identify the contacts of 16 pin AMP 174975-2 the various components: Supply Turning led 10 Oil pressure + CAN 11 Ignition key - CAN 12 - SET SWITCH 13 - High beam 14 - Fuel warning led 15 - 16 OK SWITCH...
Page 189 Electrical system Having ascertained the good condition of the fuses in question, proceed as follows: With the fuel tank removed from the motorcycle and empty of fuel, connect a small circuit composed of 12V battery and a light bulb of 12V – 1.7W to the connector of the fuel level indicator as shown in the diagram.
Page 190 Electrical system Whenever the dashboard, with the switch on the ON KEY SWITCH position, is not powered, first check the conditions of the fuse located on the starter relay and, if this should be in good condition, check the conditions of the fuse located in position 5 on the fuse box.
Page 191 Electrical system SPEED SENSOR Whenever the speed is not indicated on the dashboard and the message SPEED SENSOR appears, proceed as follows: • Check the conditions of the fuse in position 1 on the fuse box. If the fuse in question is in good condition, proceed with the check of the speed sensor as follows: Keeping the sensor connected to the system and with the key ON, use a Tester to make sure that when the...
Page 192 Electrical system HIGH BEAM HEADLIGHT In the event that the driving beam does not work, check the conditions of fuse 4. If the fuse is ok, check the continuity of the left handle- bar control connector between positions between the Y\B (yellow\blue) and the Y (yellow) wires with the dri- ving beam function selected.
Page 193 Electrical system After having checked the bulbs of the headlight, the rel- ative fuses and the controls as described herewith, proceed with checks of the relay B on the left side of the motorcycle. TURN INDICATORS In the event that turn indicators do not work, check the conditions of fuse 6 on the fuse box.
Page 194 Electrical system LICENCE PLATE LIGHT If the number plate light bulbs do not function, check the condition of fuse 3 in the fuse box; if these are ok, replace the bulb. • Remove the rear reflector, removing its fixing nuts. • Remove the fixing screw of the plate holder. •...
Page 195 Electrical system • Extract the burnt-out bulb. • Fit the new bulb. • Replace the bulb holder. • Replace the plate holder and the rear reflector. COOLING FAN SYSTEM If there is a fault in the functioning of the cooling fan, proceed with the following check:: •...
Page 196 Electrical system HORN A fault in the horn system should be checked at various points: • Check the condition of fuse 1 in the fuse box. • If the fuse is in good condition, disconnect the con- nector of the left control and check the continuity between contact 3-4 of the control with the horn but- ton pressed as in the following page under “Switches”.
Page 197 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. R.H. switch L.H. switch - 37 -...
Page 198 Electrical system POSITIONING OF ELECTRICAL SYSTEM WIRE CLAMPS Code Qty. Length Name LIST OF FASTENING CLAMPS FOR F3 675 ELECTRICAL SYSTEM CABLES 800092248 L = 82 mm Rubber clamp L 82 800092247 L = 62 mm Rubber clamp L 62...
Page 199 Electrical system For the position of the clamps for fastening electrical system F3 675 cables, refer to the layout shown below (see figs. 04-30). Battery Starter Code Code motor Position the remote switch cables above the cabling of the electrical system Protection Ø13 L=150...
Page 200 Electrical system Code Code - 40 -...
Page 201 Electrical system Code NOTE: Be careful of setting the cables and the battery connections up properly Code Code (Only for electric cabling version E) - 41 -...
Page 202 Electrical system NOTE: Check steering NOTE: Position the cable and make sure on the lh side of the vehicle the horn works Code Code Code NOTE: Position the cables under the light Code Code Code Code - 42 -...
Page 203 Electrical system Code Code Code Code Code Code - 43 -...
Page 204 Electrical system Code Code Code Only for F3 ORO Code Code Code - 44 -...
Page 205 Electrical system NOTE: Be careful to set the Code lambda probe cable up correctly Code Code NOTE: Keep the clutch cable as far away as possible from the exhaust manifolds Code NOTE: Pass the cables behind the rear brake pedal switch cable. - 45 -...
Page 206 Electrical system Code NOTE: Insert the bottom edge of the elastic ECU mounting into the engine casing Code Protection Ø13 L=150 Code + N° 2 clamps Code 800092661 Protection Ø13 L=150 + N° 2 clamps Code 800092661 NOTE: Position the connector outside of the guard - 46 -...
Page 207 Electrical system Note: Be careful to set Code the lock transmission up correctly Code Code Code Code Code Note: Be careful to Protection Ø13 correctly pass L=150 + N° 2 cables clamps Code 800092661 Code - 47 -...
Page 208 Electrical system Code Code - 48 -...
Page 209 Suspension and wheels SECTION Revision 0 - 1 -...
Page 210 FRONT FORKS F3 675 ........
Page 211 Suspension and wheels FRONT WHEEL F3 675 F3 ORO N·m 16 ÷ 18 Torque Kg·m pressure ft·lb Operation Description F3 675 F3 ORO Material Aluminium alloy Forged aluminium alloy FRONT WHEEL Dimensions 3,50” x 17” Dimensions 120/70-ZR 17 M/C (58 W) TL...
Page 212 Sospensioni e ruote FRONT WHEEL REMOVAL Place the motorcycle on the rear stand. Special tool N. 800092642 Unscrew the two fixing screws of both front calipers Front brake caliper removal and remove the calipers. Torque pressure: 42 ÷ 46 N·m Protect the disassembled calipers with pro- tective material thereby avoiding possible damage to the wheel rim.
Page 213 Suspension and wheels Remove the screw (1) on both front wheel/fork attach- ments. Unscrew the nut from the left side. Holding the wheel up with your left hand, use your right hand to push the pin towards the right part of the motorcycle.
Page 214 Suspension and wheels With the wheel spindle still mounted to the wheel, Front wheel bearing check rotate the wheel to check that the bearings are not pit- ted and rotate with a smooth action. Check also for axial (A) and/or radial (B) movement. If either condition is verified, substitute the bearings.
Page 215 Suspension and wheels Mount the flange, spacer ring and nut utilising a 14 mm spanner and a 27 mm spanner and extract the bearing as shown in the figure. NOTE Operate in the same way on both bearings. Check that the ends of the aluminium spacer and the seats of the bearings on the wheels are not scored or marked.
Page 216 Suspension and wheels Insert it on the opposite part, keeping the rim in a verti- cal position. 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 217 Tighten the 2 screws of the fork feet to the required torque Mount the two brake calipers as described in chapter H F3 675 “Brakes”. 16÷18 N•m Torque pressure: F3 675 16 ÷ 18 N·m Torque pressure: F3 ORO 19 N·m F3 ORO 19 N•m - 9 -...
Page 218 Suspension and wheels FRONT FORK F3 675 N·m 22 ÷ 24 8 ÷ 10 16 ÷ 18 Torque Kg·m pressure ft·lb Operation Description F3 675 FRONT SUSPENSION “Upside down” telescopic hydraulic fork with external and separated Type adjustment of rebound and compression damping and of spring preload Ø...
Page 219 Suspension and wheels FRONT FORK F3 ORO N·m 22 ÷ 24 8 ÷ 10 Torque Kg·m pressure ft·lb Operation Description F3 ORO FRONT SUSPENSION “Upside down” telescopic hydraulic fork with external and separated Type adjustment of rebound and compression damping and of spring preload Ø...
Page 220 Suspension and wheels FRONT FORK OVERHAUL Before removing and overhauling the front suspension components, it is advisable to remove the lower fairing, the left and right fairings, the front cowl, the left and right air intake duct covers, the air ducts, the front mud- guard as described in detail in the chapter “Fairings”.
Page 221 Suspension and wheels Slacken the screw (1) on the left clip-on handlebar. Loosen the 2 screws (2) from the steering base and Stem removal the screw (3) from the steering head. Slide the stem off while holding up the clip-on. - 13 -...
Page 222 To make it easier to loosen the screw on the right side steering head, remove the screw that holds up the front brake fluid tank beforehand. Loosen the spring pre-load adjuster until you feel it Fork tube exploding (F3 675) reach the end. - 14 -...
Page 223 Suspension and wheels Loosen the cap by approximately 1 turn. Place the fork leg in a vice, in a vertical position taking care to protect its surface against possible damage. Completely unscrew the plug and lower the sheath as shown in the figure. Perform this operation while hold- ing the leg in a vertical position.
Page 224 Suspension and wheels Unscrew the plug. Using the spanner, adjust the spring preload while locking the nut on the damping piston rod. Remove the plug (1). Remove the spring. - 16 -...
Page 225 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 environ- ment. During this phase also take the spring pre-load spacer out (1).
Page 226 Suspension and wheels Pull out the damping piston. Take care not to reverse the pumping elements on the fork while fitting it back in, and configure as follows: - Brake-pressing pumping element: fit on left leg. - Brake-releasing pumping element: fit on right leg. Remove dust cap (1), taking care not to damage the seat on the sheath.
Page 227 Measure the length of the spring and compare with the following values: - F3 675: 240 mm To replace the bushings inside the sleeve, operate using the required tool in accordance with the method described in the diagram.
Page 228 Suspension and wheels Visually check for scratches and marks on the pump rod and check that it slides smoothly inside the pump unit without chamfering. Substitute if necessary. Insert the pump into the stem and fasten it on with the relative screw.
Page 229 Then, put the dust seal in (2) by hand. While holding the sheath in an upright position, insert the spring press spacer; pour in the following oil quan- tities: - F3 675: 460 cc(*) (*): approximate quantity calculated in relation to the actual maintenance level Repeatedly move the damping piston rod up and down until the it slides smoothly.
Page 230 Check that the oil is at level "X" with reference to the upper sheath rim, measured when the sheath is com- pletely compressed. - F3 675 (**): X = 105 mm (**): N.B.: Measured with the pumping rod at the end of its stroke and the spring spacer in.
Page 231 Suspension and wheels Screw the hydraulic brake adjuster (1) on as far as it will go. Install the cap (2) complete with new o-ring, by hand, and screw it on until it hits the rod and not the nut. Tighten the plug with the prescribed torque. 20 N•m Fork leg plug tightening torque: 20 N•m - 23 -...
Page 232 Suspension and wheels Insert and screw in the complete cap (1) on the fork sli- der at the required torque. Sleeve cap torque pressure: 20 N•m Fork tube exploding (F3 ORO) Place the fork leg in a vice, taking care to protect its surface against possible damage.
Page 233 Suspension and wheels Keep in place the spring support (3) by using the pro- per spanner (special tool) and remove the top cap assembly by turning it counterclockwise. Special tool No. 8000B6877 Remove the spanner, the spring support and the spring.
Page 234 Suspension and wheels For the replacement of the outer fork sleeve bushings, use the special tool. Special tool No. 8000B6871 NOTE The above tool is made with different parts (see scheme). These parts must be alter- natively assembled together according to the operation to be performed, as shown in the following steps.
Page 235 Suspension and wheels Install the upper bushing into the outer fork sleeve by using the previously assembled tool and tapping it gen- tly with a plastic hammer, until it reaches a solid stop. Apply the prescribed grease on the outer surface of the lower bushing.
Page 236 Suspension and wheels While holding the fork leg in an upright position, pour in the following oil quantities: - F3 ORO: 420 cc (*) (*): approximate quantity calculated in relation to the actual maintenance level Repeatedly move the fork sleeve up and down until it slides smoothly.
Page 237 To ensure proper positioning of the rods, refer to the figure at right, taking care to observe fitting dimension "X": - F3 675: X = 216 mm - F3 ORO: X = 216 mm - 29 -...
Page 238 Suspension and wheels Screw in and tighten the two screws (1) at the base of the steering. Carry out this assembly correctly. A casual or inexact assembly could compromise the sta- bility and steering of the motorcycle. Fit the right-hand leg following a similar procedure. Tighten the two screws (1) at the base of the steering.
Page 239 Suspension and wheels Install the clip-on being careful of fitting the pin of the clip-on into place when the steering head is re- installed. Tighten the screws (1) to the prescribed torque pres- sure. Grease only the first threads. Torque pressure: 8 ÷ 10 N·m 8÷10 N•m Re-install the steering head making sure that it fits per- fectly in place.
Page 240 Mount the front wheel and brake callipers according to procedures contained in the previous pages. Rebound damper After properly fitting the fork assembly, adjust the front Front suspension adjustment F3 675 suspension so as to ensure optimum vehicle geometry. Spring preload Spring preload Compression damper...
Page 241 Suspension and wheels NOTE Adjustments contained in the table must F3 675 F3 ORO be carried out from initial reference posi- tions: - Spring preload: Turn counter-clockwise to end stroke. - Extended brake: Turn clockwise to end stroke. F3 675...
Page 242 Suspension and wheels STEERING ASSEMBLY F3 ORO N·m 16 ÷ 18 22 ÷ 24 Into contact Torque +10° pressure Kg·m ft·lb 2400 2400 2700 2700 Operation - 34 -...
Page 243 Suspension and wheels STEERING ASSEMBLY OVERHAUL Lift the motorcycle and rest it on the special tool. Special tool No. 8000B6789 Remove the screw (1) that clamps the steering damper Disassembly of the steering damper (F3 ORO) to the frame. Loosen the three fixing screws (2) of the steering head. Steering head removal - 35 -...
Page 244 Suspension and wheels Remove the 3 clamps from the ignition switch cable. Then remove the steering head complete with shock absorber and ignition key switch. If necessary, use a rubber mallet to slide the steering head out. Remove the steering head by disconnecting the key switch connector.
Page 245 Suspension and wheels Preliminary operations: Steering base removal - Disconnect the connectors (1) of the acoustic war- ning signal. - Disconnect the electric connectors leaving the clip- ons assembled on the forks. - Then free up the clutch cable (1), the electric cables for the flashing indicator lights (2) and disconnect the connector (3) from the dashboard.
Page 246 Suspension and wheels Using the specific tool, loosen the ring nut of the stee- ring spindle, supporting the base of the steering head. Special tool No. 800091645 Remove the ring nut that was loosened previously and remove the steering base complete with pin using the relative front stand.
Page 247 Suspension and wheels Accurately clean all the parts and check the general Steering base assembly condition. Before reassembly, grease the ball bearing ring and place it onto the steering pin. Recommended grease Agip Grease 30 Fit the lower triple clamp to the frame. Fit the upper ball bearing race after greasing it.
Page 248 Suspension and wheels To disassemble and replace the ignition key switch, it Disassembly of Ignition key switch is best to completely remove the motorcycle steering head. Remove the three ignition switch connector clamps (1). Disconnect the ignition switch connector (2). Remove the complete steering head from the motorcy- cle as described in the "Steering head disassembly "paragraph.
Page 249 Suspension and wheels Remove the 2 key switch fixing screws and extract them. When reassembling, apply the following tightening torque: 10 N·m Threadlocking product used : Loctite 243 Disassembly of the steering damper clamp (F3 Loosen the clamp (1) and slide off the damper (2). ORO) Heat the screw (3) for the clamp using a heat gun, and then unscrew it.
Page 250 Suspension and wheels Remove the anchoring from the steering head by unscrewing the two screws (4) after they have been heated, as described above. During re-assembly apply Loctite 2700 to the two Clamp assembly screws (1) that clamp the anchoring to the head. Tighten the screws to the prescribed torque pressure.
Page 251 Suspension and wheels Slide the damper into the clamp observing the direction of assembly and place it at the required distance of 35 Tighten the screw to the prescribed torque pressure. Torque pressure: 4 N·m 4 N•m Position the steering head in its housing according to Steering head assembly the inverse order of disassembly operations.
Page 252 Suspension and wheels Tighten the two front fixing screws (2) of the steering head. Torque pressure: 16 ÷ 18 N·m 16÷18 N•m Block the steering shock absorber in position by tigh- tening the fixing screw to the frame. Threadlocking product used: Loctite 2400 Torque pressure: 25 N·m 25 N•m - 44 -...
Page 253 40 ÷ 44 55 ÷ 60 70 ÷ 75 Torque Kg·m pressure ft·lb Operation Description F3 675 F3 ORO Type Progressive, single shock absorber with rebound-compression REAR SUSPENSION damping and spring preload adjustment Swingarm Aluminium alloy Aluminium alloy Wheel travel (mm) During the disassembly and check of the rear suspension assembly, it is advisable to disassemble the under- engine fairing, fairing side panels, tail unit and fuel tank as described in chapter C "Bodywork".
Page 254 Suspension and wheels Remove the seats, side panels, tank and rear panels Rear shock absorber disassembly as described in Chapter C "Fairings". Lift up the rear part of the motorcycle with the specific lifter. Slacken the upper nut (1) of the shock absorber. Using a screwdriver push the screw (2) outwards.
Page 255 Suspension and wheels Remove the bottom nut (2) of the damper and slide the screw out. Take out the complete damper. Make sure that the top connection of the damper (ball Rear shock absorber test joint) does not have any axial (A) or radial (B) play. - 47 -...
Page 256 Check the length of the rear shock absorber spring. Standard spring adjustment (A): - F3 675 (on road): A = 161,5 mm - F3 675 (on race track): A = 160,5 mm - F3 ORO: A = 142 mm Check the functioning of the adjusters.
Page 257 Suspension and wheels Accurately clean all parts. Grease the screws with Agip Rear shock absorber assembly Grease 30 before reassembly. Insert the shock absorber from above and lightly screw in the lower screw of the shock absorber using the relative nut.
Page 258 Suspension and wheels SWINGARM REMOVAL AND OVERHAUL Remove the rear damper as described in the previous pages. Remove the rubber and the safety spring clip (1) and Rear wheel removal unscrew the screw ring of the wheel. Attention! The screw ring has a left-handed thread.
Page 259 Suspension and wheels Unscrew the two screws (1) of both footrest supports and remove them. Remove the passenger foot pegs by acting on the 2 Passenger footrest removal relative screws for each side. Remove the two socket head screws (1) of the lower Lower chain guard removal chain guard.
Page 260 Suspension and wheels Remove the two top chain guard screws (1). Top chain guard removal Remove the clamping screw on the lh side. Silencer disassembly Remove the socket head screw on the right side hol- ding the nut still with a 10mm wrench. - 52 -...
Page 261 Suspension and wheels Remove the silencers unit from the exhausts. Remove the chain utilising the special tool. CHAIN REMOVAL Special tool N. 800095389. Identify the connecting link. The part of the tool being indicated must operate on the internal part of the crown wheel. NOTE The tool has three functions: •...
Page 262 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, removing both pins from the connecting link. How to fit the chain back in Before reassembling the chain, grease the connecting pins and the O-Rings as shown in the figure, by using the special grease supplied with the chain kit.
Page 263 Suspension and wheels Fit the punch and the plate holder on the tool as shown in the figure. Mount the tool onto the chain as shown in the figure and align the punch on «A». 30÷35 N•m Turn the pin holder by hand until the plate holder con- tacts with the connecting link plate.
Page 264 Suspension and wheels When the riveting is over, check if the diameter of the head of both pins is between the following range: - Pin head diameter after riveting: d = Ø 5.5 mm Loosen the two screws (1) and remove brake caliper (2). Removing the rear brake caliper Remove the speed sensor cable holding clamp (3).
Page 265 Suspension and wheels Disconnect the speed sensor cable connector (1). Before removing the swingarm pin, loosen the suspen- Swingarm pin removal sion rocker pin (1) and the two engine pins (2). (See chapter G “Frame”). Also loosen the pin for the pads. - 57 -...
Page 266 Suspension and wheels Remove the screw (1) on the left side of the vehicle. Remove the washer and push out the pin manually. At this point slide out the rocker arm pin (3). Support the swing arm to avoid it from falling on the ground and slide it towards the rear part of the motor- cycle.
Page 267 Suspension and wheels Lift up the front part of the chain guide to remove it from the swingarm (see figure). Slide out in a forward position as shown in the figure. During re-assembly, proceed in reverse order making sure that the two front and rear reference elliptical ele- ments are in the correct position.
Page 268 Suspension and wheels If it is necessary to substitute the bearings of the swin- Bearings overhaul garm because of excessive play, operate as follows: Remove the right and left spacer. Remove the Seeger retaining ring on the right side of the swingarm.
Page 269 Suspension and wheels Fitting the bearings and the roller cases on the rear swingarm. Cod. 800084938 Take two new roller cases (Part No. 800084936) and two new ball bearings (Part No. 800084938). Preassemble the 2 roller cases (Part No. 800084936) on specific tool Part No.
Page 270 N·m 30÷35 20÷22 200÷220 28÷32 220÷240 140 10 18÷20 5÷7 Torque Kg·m pressure ft·lb Operation Description F3 675 F3 ORO Material Aluminium alloy Forged Aluminium alloy REAR WHEEL Dimensions 5,50” x 17” Dimensions 180/55 ZR 17 M/C (73W) REAR TYRE...
Page 271 Suspension and wheels 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 no. 800092642 Remove the rear wheel by removing the polygonal nut. Utilise the following tools: •...
Page 272 Suspension and wheels Slacken the nut of the flange by rotating it in an anti- clockwise direction as shown in the figure. Utilise the following tools: • Torque wrench • 55 mm polygonal spanner Remove the nut (1) with the shim (2) underneath. Slacken the fixings (1) of the wheel hub.
Page 273 Suspension and wheels With the special spanner mounted on the extension tube, pull forward the eccentric adjuster and slacken the chain. Special tool: Eccentric adjuster spanner N. 800092854 Spanner extension N. 800092855 Remove the rear sprocket unit (3) and the spacer ring (5) underneath.
Page 274 Suspension and wheels Slacken the two screws (6) and remove the brake cali- per (7). Remove the wheel spindle complete with the brake Disassembly of the wheel pin disc, extracting it from the right side of the motorcycle as shown in the figure. At the same time, support the ring gear unit with one hand.
Page 275 Suspension and wheels Extract the wheel hub from the left side of the fork. Wheel hub disassembly Carefully wash all parts. Check the condition of the roller bearing and the ball bearing. If there is excessive play (even only one of the bea- rings) or chamferings during rotation, substitute the wheel hub, complete with bearings with a new unit.
Page 276 Suspension and wheels Check the condition of the wheel drive engagement Wheel spindle unit check splines. If it is worn, substitute as follows. Disassemble the phonic wheel by acting on the 4 screws (1). Remove the four clamping screws (1) of the brake disc holder flange, as they are usually assembled with threadlocker fluid, after having heated them with a heat gun.
Page 277 Suspension and wheels 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. 20÷22 N•m When assembling, apply force on the crown of the peg not on the point.
Page 278 Suspension and wheels Evaluate the state of wear of the ring gear. If it appears to be too worn, proceed as described in the following operation. Extract the 5 spring drives (2) from the gear flange sup- Flexible coupling check port (3) and assess its condition.
Page 279 Suspension and wheels If the bushes are excessively worn, replace the entire set of flanges. When the ring gear unit is being re-assembled with the drive flange unit, grease the coupling areas. Bushes coupling area (1): Grease AGIP GR SM Bushes coupling area (2): Grease AGIP GREASE 30 Do not apply grease to the threads of the pins.
Page 280 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 281 Suspension and wheels Reassemble the brake caliper (1) and tighten the fixing screws (2) at the specified torque. 18 N•m Special product: Loctite 243 Torque pressure: 18 N•m Reinsert the rubber clamp (1) around the rear brake pipe. Reposition the nut of the flange (1) with the relative washer (2) without tightening.
Page 282 Suspension and wheels Using the special spanner, bring the eccentric back into position by rotating in an anti-clockwise direction to tighten the chain. Special tool: Spanner for eccentric hub N. 800092854 Extension for spanner N. 800092855 Tighten the two fastening elements (1) of the wheel hub.
Page 283 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 81. Insert 1st gear. Reassemble the rear wheel. Tighten the wheel axis nut to the prescribed torque pressure.
Page 284 Suspension and wheels Pinion disassembly Remove the fastening elements of the gear extension (1). Remove the fastening elements of the left foot peg (2). Remove the gear extension and the foot peg to access the pinion cover. Remove the 3 clamping screws (2) and remove the pinion cover (1).
Page 285 Suspension and wheels Straighten the metal tongue with a flat-head drift and hammer. Put it in first gear by moving the lever clockwise by hand. Heat the nut with a heat gun. Unscrew the pinion wheel retaining nut. Now cut and remove the chain as described on pages 53-54.
Page 286 Suspension and wheels Using the specially designed spanner, remove nut (1) and washer (2). Remove the pinion and replace it with a new pinion. For reassembly, insert the pinion to end stroke. Take a new washer, assemble it with the nut and tight- en to the prescribed torque pressure utilising Loctite thread-locking fluid.
Page 287 NOTE Two persons must carry out this opera- tion. Check that dimension X1 is equal to: = 300 mm = 300 mm F3 675: F3 ORO: - 79 -...
Page 288 If the value differs, act on the spring pre-load adjust- ment ruing nut using the required tool, in either one direction or the other depending on the calculated value of Δ static sag. - F3 675: Turn anticlockwise Turn clockwise Special tool no. 75 mm hook wrench Δ...
Page 289 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 290 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 the special tool cod.
Page 291 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 292 Suspension and wheels - 84 -...
Page 293 Frame SECTION Revision 0 - 1 -...
Page 294 Frame SUMMARY BATTERY CABLES ..............PAGE 3 SIDE STAND REMOVAL .
Page 295 Frame BATTERY CABLES It is a good rule to disconnect the battery cables before removing components from the motorcycle. Remove the cowl and tank as described in chapter C "Bodywork". Remove the screw (1) indicated in the figure Disconnect the negative pole of the battery. When removing the battery, it is necessary to remove the negative pole cable first and then the positive pole cable.
Page 296 Frame Remove the battery from its compartment. Remove the battery mounting by unscrewing the 3 screws. Remove the 4 Relais (2 per side). - 4 -...
Page 297 Frame If it is necessary to remove the engine power and earth cables, once the battery has been removed as descri- bed above, remove the screws as shown in the figure. - 5 -...
Page 298 Frame SIDE STAND REMOVAL If the side stand needs to be replaced, use the fol- lowing procedure: Place the motorcycle on the rear stand (special tool). Special tool No. 800092642 Remove the side fairings and the underfairing as described in the chapter "Superstructures." Disconnect the electrical connector of the safety switch(1).
Page 299 Frame For reassembly, proceed in the reverse order of remo- val. Apply the recommended thread-locking liquid to the 2 plate fixing screws. Tighten to the prescribed torque pressure. Tightening torque for the stand plate screws (6): 40 ÷ 44 N·m Recommended thread-locking liquid: Loctite 40÷44 N•m Side stand switch screw tightening torque...
Page 300 Frame FOOT PEG REMOVAL Before disassembling the left foot peg remove the clamping screw (1) from the gear extension. On the right foot peg, also remove the silencer clamping screw (2). Act on the 2 screws (1) of both foot peg mountings and remove them.
Page 301 Frame Remove the clamping screw on the lh side. EXHAUST SILENCER DISASSEMBLY Remove the socket head screw on the right side hol- ding the nut still with a 10mm wrench. Pull the silencer unit out from the exhausts. - 9 -...
Page 302 Frame EXHAUST TUBE REMOVAL NOTE: This operation is not necessary for disas- sembly of the engine or frame. Proceed as descri- bed below for exhaust manifold replacement. Disassemble the water radiator and oil radiator befo- rehand, as described in chapter L "Cooling system". Slide off the Lambda probe connector (1) and lift.
Page 303 Frame Remove the manifold as indicated in the figure. Disassemble the metal sealing gasket (3) in the head. Apply sufficiently adequate wadding to the exhaust ports to stop the entry of dirt and dust into the cylin- ders. If the engine has to be removed from the frame, it will be necessary to remove the chain as described in chapter F “Suspension and wheels”.
Page 304 Frame FRAME REMOVAL PRELIMINARY OPERATIONS Support the motorcycle with the aid of the following stands: - Cod. 800092642: Rear stand - Cod. 800095807: Front stand - Cod. 8000B7340: Front stand pin - Cod. 8000B6789: Engine support Remove the following components in order: - Front mudguard - Front brake callipers - Front wheel...
Page 305 Frame THROTTLE BODY REMOVAL Remove the 2 cable-retaining clamps (1). Remove the pressure sensor (2). Disconnect the 3 injector connectors (3). - 13 -...
Page 306 Frame Disconnect the 6 clamping screws (4) of the throttle body. Lift the throttle body as shown in the figure. Disconnect the DBW control connection (5). - 14 -...
Page 307 Frame Protect the air intake lines using adhesive tape in order to avoid dirt from getting into the cylinders. Re-assemble following the disassembly instructions in reverse order. Remove the following components in order: - Steering head - Acoustic warning signal - Right/left handlebars - Right/left front forks - Steering base...
Page 308 Frame PLUG-TOP COIL DISASSEMBLY Remove the 3 screws (1) and the clamping bracket (2) for the plug-top coils. Take the 3 plug-top coils out, as shown in the figure. Remove the 2 clamping screws from the connector located on the flange of the throttle body. - 16 -...
Page 309 Frame Disconnect the electrical connections as shown in the figure. Slide the electrical connections out. Take the reel unit off. - 17 -...
Page 310 Frame REMOVING THE BATTERY BOX Remove the entire ECU. Remove the 3 screws (2) that clamp the battery box to the frame. Disconnect the 4 relais (2 per side). - 18 -...
Page 311 Frame Take off the battery box. REMOVING THE SOLENOID STARTER Disconnect the connection to the starter motor. Disconnect the connector of the main system. - 19 -...
Page 312 Frame Remove the clamping screw for the remote switch mounting plate. Remove the solenoid starter, including its cables. REMOVING THE MAIN CABLING To remove the main cabling it is necessary to discon- nect all of the connections and remove the clamps. Free up the connection for the direction indicators.
Page 313 Frame Remove the fuse panel. Remove the engine rpm pick-up. Remove the current generator connection. - 21 -...
Page 314 Frame Remove the gear position sensor. Remove the engine coolant temperature sensor. Remove the rear wheel speed sensor. - 22 -...
Page 315 Frame Position all of the cabling over the rear frame. REMOVING THE PASSENGER SEAT LOCK Remove the 2 nuts that clamp the lock to the frame REMOVING THE FUSE PANEL MOUNTING PLATE Remove the screw that clamps the fuse panel moun- ting plate to the frame.
Page 316 Frame REMOVING CLUTCH CONTROL TRANSMISSION Loosen the nut on the clutch cable. Unhook the transmission from the lever. Unscrew the counter-nut to free up the transmission from the plate. - 24 -...
Page 317 Frame REMOVING THE FRONT COWL MOUNTING Remove the 2 screws that clamp the cowl mounting FRAME frame to the frame. Remove the front cowl mounting frame. FRAME DISASSEMBLY Unscrew and remove the right side front fixing nut. Remove the spindle from the left side of the frame. - 25 -...
Page 318 Frame Unscrew and remove the upper rear fixing screws from both sides of the frame. Unscrew and remove the engine fixing nut from the right side of the frame. Take the engine clamping pin out from the lh side of the frame.
Page 319 Frame Supporting the front part of the frame, shift it towards the front. Remove the frame from the engine by lifting. FRAME CHECKS AND INSPECTION Clean thoroughly and check the housings of the stee- ring bearings. - 27 -...
Page 320 Frame Make sure that none of the surfaces of the housings have signs of impact or dents. Using a bore meter, check circularity of the housing of the bearing in the marked cylindrical area. Check that there are no dents or evident breakage on frame tubes.
Page 321 Frame FRAME MEASUREMENTS CONTROL DIAGRAM - 29 -...
Page 322 Frame Steering bearings housing check Check the diameter and for any ovalisation on the stearing beerings as shown in the drawing here to the side. Measure ovalisation in different points as shown in the diagram. - 30 -...
Page 323 These components can be assembled on the new frame after having carried out a careful inspection. Contact MV AGUSTA spare parts service for approval punching and decals on the new frame. Carefully clean the frame-engine head and frame- rear suspension plates coupling planes.
Page 324 Frame Once the frame has been re-installed, re-install the electrical cabling. See Chapt. E - Electrical System regarding the positio- ning and passage of cables, clamps and wiring. - 32 -...
Page 325 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 326 Frame - 34 -...
Page 327 Frame REAR FRAME DISASSEMBLY If it is necessary to disassemble only the rear frame from the motorcycle, it is necessary to free up the cabling from the rear area beforehand, and bring it to the front area. Remove the four (two on each side) frame fixing screws.
Page 328 Frame FRAME PLATE REMOVAL Cut the chain as described in chapter F "Suspension and Wheels." Remove the brake oil tank in the inside of the right plate. Loosen the nut on the rh bottom engine pin. Loosen the rh side swing arm pin screw. - 36 -...
Page 329 Frame Loosen the nut on the screw that joins the plates on the rh side. Loosen the nut on the top damper connection. Counter the suspension rocker arm with a support. - 37 -...
Page 330 Frame Remove the nut on the rh side plate rocker arm pin. Take out the lh side plate rocker arm pin. Remove the nut from the top damper connection, being careful not to let the suspension fall. - 38 -...
Page 331 Frame Remove the screw on the rh side swing arm pin. Remove the screw and nut that join the plates. Remove the nut of the rh side bottom engine clamping pin. - 39 -...
Page 332 Frame Remove the right plate along with the bushing. Remove the left plate with relative pins.. After these operations the engine is separate from the rear suspension. - 40 -...
Page 333 Frame RE-ASSEMBLY OF THE VEHICLE To re-assemble the vehicle in an easy fashion, do the following: - position the engine on tool 8000B6789 - assemble the following parts: 1) engine earth cable 2) electrical system protection 3) engine oil vapour vent pipe - proceed in the reverse order of disassembly of the frame plates REAR FRAME UNIT ASSEMBLY...
Page 334 Frame EXHAUST VALVE TRANSMISSIONS ASSEMBLY AND ADJUSTMENT Take exhaust valve actuator (Code 8000B2126) and make sure that the top opening (1) on the pulley is aligned with the symbol (2). Position the terminals on the exhaust valve actuator as shown in the figure. Push the sheaths of the transmis- Closing sions (3) until they touch the actuator.
Page 335 Frame Arrange the transmission cables for the exhaust valve along the left side of the motorcycle. Position the ter- minals on the bracket and on the exhaust valve as shown in the figure. Be careful to make the transmis- sions correspond with the relative opening (2) and clo- sing (1) functions.
Page 336 Frame Insert the clamping plate (code 8000B4110) onto the bracket. Insert the M5 clamping screw (code 8B00B2680) and M5 nut (code 8000B2707) onto the plate. Tighten the fastening elements to the max required torque. 2 N•m Torque pressure: clamp. screw Plate: 2 N·m Slide off the rubber caps from the transmissions to free up the adjusters.
Page 337 Frame Proceed with the adjusting procedure of the opening and closing transmissions so as to place the bottom pulley lock against the plate (1). Make sure that in this position the transmissions are adjusted with a clearan- ce that allows the pulley to rotate slightly. Carry out the self-learning procedure on the all the way open/all the way closed positions of the valve.
Page 338 Frame Fasten the exhaust valve actuator (1) by inserting it on the clamping pegs (2) located on the inside of the side panelling of the lh side panel fairing as shown in the figures. - 46 -...
Page 339 Brakes SECTION Revision 0 - 1 -...
Page 340 FRONT BRAKE PADS SUBSTITUTION (F3 675) ........
Page 341: Front Brake System
Brakes FRONT BRAKE SYSTEM F3 675 F3 ORO N·m 8÷10 42 ÷ 46 23 ÷ 26 16 ÷ 18 5 ÷ 7 23 ÷ 25 Torque Kg·m pressure ft·lb Operation Description F3 675 F3 ORO FRONT BRAKE Type Dual floating disc with steel braking band Ø...
Page 342 Brakes FRONT BRAKE PADS SUBSTITUTION (F3 675) Using pincers, position the pin (1), in such a way as to facilitate seeger removal. Remove the two seegers (2), one for each pin. Remove the two pins (1) and remove the pad cover (3).
Page 343 Brakes Widen the pads before taking them out. Remove the two pads from the caliper. Repeat the same disassembling procedure for the other caliper. Every 6000 kilometres, check the wear of the pads. The pad thickness must not be less than 1 mm. If the pads are excessively worn, substitute them.
Page 344 Brakes To replace the front brake pads, remove the front brake FRONT BRAKE PADS SUBSTITUTION (F3 ORO) caliper, as detailed in the “Suspensions and Wheels” section. Widen the pads with a screwdriver so that the pistons are pushed back into their seats (as shown in the figu- re).
Page 345 Fit the caliper back in but do not tighten the screws. F3 ORO F3 675 Operate the front brake lever to position the pistons (pushing against the pads). While pulling the front brake lever, tighten the caliper screws to the right torque.
Page 346 Position the wrench, then apply a rubber tube to the bleeder screw of both calipers, right and left (on top of the brake calliper). F3 675 Put the other end of the rubber tube in a suitable con- tainer. F3 ORO...
Page 347 Tighten the bleed screw, remove the rubber tube, care- fully clean the screw with alcohol, blow it dry and put the F3 ORO protective cap back on. Bleed screw tightening torque: 6 Nm (F3 675) Bleed screw tightening torque: 8 Nm (F3 ORO) F3 675 - 9 -...
Page 348 Brakes Remove the protection cap of the bleed screw of the caliper. Introduce an 8mm wrench and connect the rubber tube for collecting the brake fluid. Holding the brake lever engaged, loosen the bleeder screw and close it back up, all the while engaging the brake lever.
Page 349 Brakes Pour new brake fluid into the chamber until it reaches the maximum level. Brake Fluid : AGIP Brake 4 Utilise only the prescribed brake fluid from sealed containers. NEVER use old or used brake fluid. Top-up the level of the fluid until it reaches the maxi- mum mark (upper).
Page 350 Brakes Accurately clean the three elements of the brake fluid chamber cap with alcohol and dry with compressed air. Position and screw on the top brake fluid tank cap firmly holding onto the tank. Reposition the safety tab and fasten it on with the screw that was removed previously.
Page 351 Brakes FRONT BRAKE CALIPERS SUBSTITUTION • Slightly move the front brake lever towards the right handgrip and hold it in position with a strap to limit the outflow of brake fluid during subsequent opera- tions. • Unscrew the fitting with a 12mm key, being careful to avoid spilling any brake fluid.
Page 352 Brakes To fit the front brake calipers, follow these steps: • Insert the caliper fixing screws and turn them it until they make contact. 23÷26 N•m 42÷46 N•m Only grease the first threads of the brake caliper fixing screw. • Refit the caliper connection after replacing the sea- ling washers.
Page 353 Brakes Remove the union (3) indicated in the figure. Brake fluid is extremely corrosive. Avoid contact with the eyes, skin and nose. Wash abundantly with water and call a doc- tor if accidental contact occurs. During the following operations, avoid con- tact with painted surfaces.
Page 354 Brakes During the assembly phase, be careful of the position of the brake pipe fitting and use two new washers. Place the pump close to the handlebar pipe and fasten it with the clamp being careful that the "UP" sign is facing upwards and that the position of the pump cor- responds to the reference marked on the handlebar pipe.
Page 355 Brakes Make sure that the connecting pipe to the pump does not have any cracks or signs of wear. If necessary replace it by loosening the retaining clamp, sliding it out from the work area and pulling out the pipe from the pump line as well. To re-assemble it perform the procedure in reverse order, being careful of the pipe position and orientation.
Page 356 Brakes Remove the nut shown in the figure. BRAKE LEVER REMOVAL Unscrew the pin. Remove the brake lever. 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 - 18 -...
Page 357 Brakes For the reassembly of the lever tighten the pin. Tighten the nut while holding the pin in place with a flat blade screwdriver. 5÷7 N•m Torque pressure: 5 ÷ 7 N·m Check the thickness of the front discs utilising a micro- FRONT BRAKE DISCS meter gauge and measure three points at least with 120°...
Page 358 Brakes Take down the front wheel as described in chapter F FRONT BRAKE DISC REMOVAL "Suspensions and Wheels". Place the wheel in a horizontal position and remove the five screws of each disc proceeding in a star-like mode for the removal. Visually check the discs for lines or score marks.
Page 359 Brakes The following operation is to be carried out on all models. If newly supplied screws are being used they already have threadlocker on them. Apply thread-locking fluid to the five fixing screws of the disc. Recommended thread-locking fluid : Loctite Screw in the screws lightly, proceeding in a star-like mode.
Page 360: Rear Brake System
18 ÷ 20 16 ÷ 18 8 ÷ 10 Torque Kg·m pressure ft·lb Operation Description F3 675 F3 ORO REAR BRAKE Type Single steel disc Ø discs (mm) Caliper (Ø pistons mm) With 2 pistons Ø 34 Rear disc thickness (mm) Min.
Page 361 Brakes Remove the safety retainer and unscrew the rear ring REAR BRAKE PADS SUBSTITUTION nut by turning it clockwise (see figure). Remove the wheel. Utilising circlip pincers as shown in the figure, widen the pads so that the pistons are pushed back into their seats.
Page 362 Brakes Slide the pad supporting pin (1) off with a screwdriver until it comes out from the opposite side, freeing up the circlip as well (2). Remove the pad (3) by letting it drop down. Remove the caliper from the support by removing the 2 fixing screws.
Page 363 Brakes SUBSTITUTION AND BLEEDING OF THE REAR BRAKE FLUID The operation described herewith must be carried out with the engine cold because of the nearness of the exhaust tubes that could cause grave burns. To carry out this operation it is necessary to remove the tank (1) along with the supporting bracket (2) from the frame plate, and then detach it from the bracket.
Page 364 Brakes Connect a rubber tube to the bleed valve, empty the system in an appropriate container by slackening the bleed valve as shown in the figure Be careful not to let the liquid fall below the minimum level before topping it up with new brake oil, to avoid getting air into the system.
Page 365 Brakes To facilitate the operation, remove the brake pads as REAR BRAKE CALIPER SUBSTITUTION described previously. Empty the rear brake system as previously described in the paragraph “SUBSTITUTION AND BLEEDING OF THE REAR BRAKE FLUID”. Loosen the tubing by unscrewing the union indicated in the figure.
Page 366 Brakes Assemble the union tightening to the prescribed tor- que. 23÷26 N•m Torque pressure: 23 ÷ 26 N·m NOTE Substitute the gaskets with new ones. Proceed with the filling and bleeding of the rear brake system (see page 25). Carry out the emptying of the brake system as pre- Rear brake pump removal viously described.
Page 367 Brakes Disengage the switch cabling by removing the two marked rubber clamps. Unscrew connection (1) as shown in the figure so as to disengage the pump from the brake line. Loosen the retaining clamp by sliding it out of the work area and pull out the brake fluid pipe.
Page 368 Brakes After having carried out a check on all components and substituted those used, damaged or defective proceed with the assembly by following the procedure in rever- 16÷18 N•m se order of removal. Substitute the gaskets of the pump/caliper NOTE hoses.
Page 369 Brakes - Remove the four nuts fastening the disc to the flan- Check the planarity of the rear brake disc by utilising a micrometer gauge and placing the disc on a level work surface. Utilise the same procedure adopted for the front wheel discs.
Page 370 Brakes Before fitting the rear brake disc, check the condition of the four pins. Replace the four special nuts with new ones. Proceed with tightening of the nuts. Turn in the nuts until they make contact, then tighten them in a crosswise pattern. Recommended threadlocking product:...
Page 371 Cooling system SECTION Revision 0 - 1 -...
Page 372: Cooling System
Cooling system SUMMARY COMPLETE COOLING SYSTEM ASSEMBLY ..........PAGE 3 COOLING SYSTEM LEAKAGE CHECK .
Page 373 Cooling system COMPLETE COOLING SYSTEM ASSEMBLY Before proceeding with the disposal or overhaul of any component relative to the cooling system, carry out cer- tain preliminary operations: 1) Let the engine cool down. 2) Remove the side fairings, the underfairing, the fairings push rod, the headlight fairing, the suction duct covers and suction ducts as described in the chapter "Superstructures."...
Page 374 Cooling system COOLING SYSTEM LEAKAGE CHECK Before removing the radiator and discharging the engine coolant, check that the cooling system does not have leakages. Remove the water radiator cap and connect the tester (of the type shown in the diagram) to the filler hole. Do not open the radiator cap whilst the engine is hot.
Page 375 Cooling system ENGINE COOLANT EXTRACTION Remove the water radiator cap. Empty the cooling system of the coolant as follows: • Place under the engine a container to collect the dis- charged coolant. • Remove the drain screw (1) situated on the engine. •...
Page 376 Cooling system WATER RADIATOR DISASSEMBLY After having emptied the cooling system, proceed as follows to remove the radiator: - Remove the system retaining clamp. - Disconnect the connector of the water radiator elec- tric fan of the right side of the motorcycle. - Disconnect the water temperature sensor connector from the left side of the motorcycle.
Page 377 Cooling system - Disconnect the 4 retaining radiator pipe clic clamps. One clamp is located on the left side of the vehicle. The other 3 clic clamps are located on the right side of the vehicle. - Disconnect the 4 pipes to drain away any fluid remaining in the basin - Take off the screw on the right side that clamps the water radiator to the oil radiator.
Page 378 Cooling system - Disengage the oil radiator from the pin as shown. - Pull the oil radiator towards the right and disengage it from the supporting pin. Leave it hanging from the engine by it pipes. - Take off the bottom central water radiator clamping screw.
Page 379 Cooling system - Take off the top right side water radiator clamping screw. Lower the left side of the radiator and push it towards the right to slide it out from the top sup- porting peg. Pull the radiator out from the left side, turning it as shown in the figure.
Page 380 Cooling system If necessary replace the bottom water connecting pipe, remove the clic clamp at the end of the radiator loading pipe on the left side of the motorcycle. Special tool: CLIC 205 pincers Remove the pipe. Before carrying out this operation place a collecting container under the engine to collect any residual liquid.
Page 381 Cooling system The basin includes a cap, a relief pipe and a connect- ing pipe to the previously-assembled water radiator. DISASSEMBLY OF THE WATER RADIATOR PARTS Disassembly of the electric fan Remove the 2 screws that clamp the conveyor to the radiator..
Page 382 Cooling system Turn the conveyor by 180° and unscrew the 4 screws that clamp the fan to the conveyor. Disassembly of the radiator clamping elements Slide off the 2 threaded circlips. - 12 -...
Page 383 Cooling system Slide the 2 spacers off of the bottom supporting brack- ets. Remove the anti-vibration elements from the 3 bottom clamping brackets. Remove the 2 anti-vibration elements from the air con- veyor bracket. - 13 -...
Page 384 Cooling system Slide the spacer off of the top left supporting bracket. Slide the anti-vibration elements off of the 2 top sup- porting brackets. Disassembly of the liquid temperature sensor Whenever it is necessary to check whether the liquid temperature sensor is operating efficiently proceed as described below.
Page 385 Cooling system Remove the coolant liquid temperature sensor. Check Check that the resistance of the coolant liquid temper- ature sensor varies with the temperature, as specified. Carry out the control in accordance with the instruc- tions below: connect the coolant liquid temperature sensor to an ohmmeter and immerse it in the oil contained in a heat- ed recipient;...
Page 386 Cooling system Assembly of the liquid temperature sensor Before assembly apply the stated type of threadlocker 18 N•m fluid to the threaded section of the sensor. Types of applicable threadlocker: Loctite 577 Tighten the coolant liquid temperature sensor to the specified torque pressure.
Page 387 Cooling system Position the electric fan on the radiator. Position electric fan wiring as indicated in the figure. Tighten the 2 screws to the prescribed tightening torque. Torque pressure: 5 ÷ 6 N·m Replace the previously removed components following the disassembly procedures inversely. 5÷6 N•m The assembly of the new radiator group has been completed.
Page 388 Cooling system THERMOSTAT REMOVAL Remove the 2 fixing screws of the thermostat cover. Remove the cover of the thermostat (1). Remove the thermostat (2). - 18 -...
Page 389 Cooling system Check 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 threaded through the flange as indicated in the figure. • Immerse the thermostat in water contained in a labo- ratory glass as indicated in the figure.
Page 390 Cooling system THERMOSTAT ASSEMBLY 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 391 Cooling system Insert the thermostat cover on the engine. Tighten the 2 fixing screws to the prescribed torque pressure. Torque pressure: 8 N·m 8 N•m WATER RADIATOR VEHICLE UNIT ASSEMBLY Reassemble the radiator unit in the opposite order of disassembly. - 21 -...
Page 392 Cooling system OIL RADIATOR DISASSEMBLY To disassemble the oil radiator with its pipes, it is also necessary to disassemble the water radiator and exhaust manifold beforehand. Remove the 3 clamping screws for the pipe retaining plate and slide it off downwards. Position an oil collecting basin under the pipes.
Page 393 Cooling system Make sure the part is intact and of necessary straight- en the folded flaps with a screwdriver. OIL RADIATOR COMPONENT DISASSEMBLY Removing the connecting pipes Take the retaining screw off of the plate. Slide the pipe off. Do the same with the other one. - 23 -...
Page 394 Cooling system Removing the plate that fastens on the fairing tip Lift and move the plate flaps away using a screwdriver. Remove the plate that fastens on the fairing tip. - 24 -...
Page 395 Cooling system OIL RADIATOR ASSEMBLY Before reassembly, check the integrity of the oil tubes and replace if necessary. Change the sealing rings for the oil pipe fittings every time they are disassembled. Grease O-rings with silicone grease. Proceed to re-assemble the previously removed parts following the disassembly instructions in reverse order, 10 N•m being careful not to put the pipes in backwards, con-...
Page 396 Cooling system Put in and tighten the two clamping screws (2) for the return pipe plate first, then proceed to put in and tight- en the screw (3) keeping the return pipe resting on its seat. WARNING: Do not turn the pipes once the screws have been tightened Once the screws have been tightened, make sure that the pipes are set up in the direction shown in the fig-...
Page 397 Cooling system FILLING THE COOLING SYSTEM Position the motorcycle on the side stand. Fill the cooling system with the required liquid described in the table (see page B-8) up to the level of the radiator fill cap. Carry out the operation several times until the level of the liquid is stable.
Page 398 Cooling system MOTOR OIL SYSTEM FILLING Unscrew the oil fill cap. Pour in the required quantity of oil. Make sure that the oil level is between the MIN and MAX level markings on the fill cap control rod. Oil level Before replacing the filler plug, grease O-ring (1) with silicone grease, then reinsert it into its seat (see fig- ure).
Page 399 Cooling system SYSTEM FUNCTIONING CHECK Assemble the following components in order: • Airbox. • Fuel tank. • Rear side panels. • Fuel tank side panels. • Air intake ducts. • Front fairing. • Left and right fairings. • Under fairing. For the assembly operations, assemble in reverse order of removal.
Page 400 Cooling system - 30 -...
Page 401 Special tools SECTION Revision 0 - 1 -...
Page 402 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 403: Special Tools
Special tools Code Q.ty Note F3 675 F3 ORO Descrizione Description 800095830 • • Cavalletto anteriore Front stand 800091645 • • Chiave ghiera Steering bearing cuscinetti di sterzo pin wrench 8000B6876 • Attrezzo per Tool for fork cap tappo superiore 800092860 •...
Page 404 Special tools - 4 -...
Page 405 Special tools Code Q.ty Note F3 675 F3 ORO Descrizione Description 8000B6782 • • Attrezzo montaggio Equaliser pacco bilanciere pack tool 8000B4421 • • Attrezzo cuscinetti Front wheel ruota anteriore bearings tool 800095389 • • Attrezzo catena Chain tool 800095390 •...
Page 406 Special tools - 6 -...
Page 407 Special tools Code Q.ty Note F3 675 F3 ORO Descrizione Description 8000B7177 • • Attrezzo montaggio Gear change cambio mounting tool 800079015 • • Attrezzo bloccaggio Clutch blocking frizione tool 8000B7293 • • Tampone per sede Pad for exhaust valvola scarico...
Page 408 Special tools - 8 -...
Page 409 Tightening torques SECTION Revision 0 - 1 -...
Page 410 Tightening torques - 2 -...
Page 411 Tightening torques - 3 -...
Page 412 Tightening torques - 4 -...
Page 413 Tightening torques - 5 -...
Page 414 Tightening torques - 6 -...
Page 415 Diagnostic SECTION Revision 0 - 1 -...
Page 416: Diagnostic
Diagnostic ELECTRICAL COMPONENTS BATTERY CHARGING SYSTEM Check the condition of the fuse on the remote switch Replace Battery warning light on Faulty fuse connection on remote switch Deoxidize/Repair Faulty remote switch connection Deoxidize/Repair Battery connection defective Deoxidize/Repair Battery faulty Replace Alternator broken Replace Alternator connection defective Deoxidize/Repair...
Page 417 Diagnostic Bulb burnt out Replace Bulb connections faulty Deoxidize/Repair Low beam does not work Faulty front light connection Deoxidize/Repair Check condition of fuse 4 Replace Fuse 4 connection faulty Deoxidize/Repair Lights switch broken Replace Lights switch connection faulty Deoxidize/Repair Lights switch broken Replace Lights switch connection faulty Replace...
Page 418 Diagnostic Instrument panel broken Replace Instrument panel connection faulty Deoxidize/Repair Battery warning light does not work ECU failure Replace Faulty ECU connection Deoxidize/Repair Gear position sensor broken Replace Gear position sensor connection faulty Deoxidize/Repair The idle light does not come on Instrument panel broken Replace Instrument panel connection faulty...
Page 419 Diagnostic DIAGNOSTICS DASHBOARD INSTRUCTIONS Faulty pressure sensor connection Deoxidize/Repair Rubber fitting pipe damaged or not connected Repair/Replace PRESSURE SENSOR Pressure sensor damaged Replace Faulty ECU connection Deoxidize/Repair ECU failure Replace Problem with the electrical system Repair/Replace See above Faulty air temperature sensor connection Deoxidize/Repair PHASE ERROR AIR TEMP...
Page 420 Diagnostic Faulty specified reel connection Deoxidize/Repair Specified coil broken Replace COIL N ECU failure Replace Faulty ECU connection Deoxidize/Repair Problem with the electrical system Repair/Replace Faulty fan relay connection Deoxidize/Repair Fan relay failure Replace FAN RELAY ECU failure Replace Faulty ECU connection Deoxidize/Repair Problem with the electrical system Repair/Replace...
Page 421 Diagnostic FRAME STEERING Steering bearings damaged Replace Steering stiff Steering bearings overtightened Adjust Steering pin bent Replace Steering damper action excessive Adjust Steering damper joints damaged Replace Tyre pressure low Adjust Vehicle tends to steer or does not travel on a straight line Fork bent Replace Frame bent Replace...
Page 422 Diagnostic Spring preload excessive Adjust Hydraulic compression damping (high/low speed) excessive Adjust Rear suspension stiff Hydraulic rebound damping excessive Adjust Tyre pressure high Adjust Swingarm bearings damaged Replace Swingarm rocker bearings damaged Replace Shock absorber joints damaged Replace Suspension linkage joints damaged Repair Swingarm pin bent Replace...
Page 423 Analytical index SECTION Revision 0 - 1 -...
Page 424: Nuts And Bolts
Warning lights and instrumentation ..B-57 ANALYTICAL INDEX - F3 675 WORKSHOP MANUAL Glossary and symbols ....A-4 Section A - General Description Air intake system .
Page 425 ... .H-16 Front forks F3 675 ..... .F-10 Section F - Suspension and wheels –...
Page 426 Maintenance tools ..... .M-2 Section M - Special tools Frame tightening torques F3 675 ..N-2 Section N - Torque pressure Frame tightening torques F3 ORO .

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