MV Agusta Rivale 800 Workshop Manual

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  • Page 2 © 2014 The reproduction, even partial of this document is forbidden without prior written agreement of MV Agusta Motor S.p.A. Part no. 8A00B8457 - Edition no. 1 Printed – April 2014...
  • Page 3 Motorcycle workshop manual MV AGUSTA RIVALE 800...
  • Page 4 Everything that we do has repercussions on the entire planet and its resources. MV Agusta, wanting to protect the interest of the people, would like to make the client and the technicians of the technical assistance centres aware and to adopt modalities of use of the motorcycle and the disposure of its parts in full respect of the norms in force in terms of environmental pollution, disposal and the recycling of waste.
  • Page 5 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 ....................Rev.
  • 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 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 General description GLOSSARY AND SYMBOLS This signifies that the lack ATTENTION incomplete Use the recommended suspension fluid. obser vance of this advice can be gravely dangerous for your safety and for the safety of other persons. This signifies that the lack Use the recommended coolant.
  • Page 11 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 2 Cylinder 3 Cylinder 1...
  • Page 12 • 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 • 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 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 TECHNICAL DATA .
  • Page 19: Technical Information

    Maintenance TECHNICAL INFORMATION TECHNICAL DATA Description RIVALE 800 CHARACTERISTICS Wheelbase (mm) (*) 1410 Total length (mm) (*) 2070 Maximum width (mm) Seat height (mm) (*) Ground clearance (mm) (*) Trail (mm) (*) 104.5 Dry weight (kg) Fuel tank capacity (lt) (**) 12.88...
  • Page 20 Maintenance TECHNICAL DATA Description RIVALE 800 TIMING Type Double-overhead camshaft LUBRICATION Type Wet sump IGNITION - FUEL FEED SYSTEM Type Eldor EM2.0 “NEMO” integrated ignition-injection system with Mikuni Motorised throttle body; inductive discharge electronic ignition; “Multipoint” phased sequential electronic injection.
  • Page 21 Maintenance TECHNICAL DATA Description RIVALE 800 TYRES Front 120/70 ZR 17 M/C (58 W) TL Rear 180/55 ZR 17 M/C (73 W) TL 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

    Everything that we do has repercussions on the whole planet and on its resources. MV Agusta, to protect the interests of the everyone, ask clients and technical assistance operators to use the motorcycle and dispose of its used parts with respect to the norms in force in terms of environmental pollution, disposal and recycling of refuse.
  • Page 23 Maintenance Programmed maintenance schedule 1000 6000 12000 18000 24000 30000 36000 Km (mi) (600) (3800) (7500) (11200) (14900) (18600) (22400) Pre- Service delivery Description Operation ● ● ● ● ● ● ● ● Check / adjust Transmission and flexible controls ●...
  • Page 24 * : 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 Rivale 800 engine. If the described oil is not available, MV Agusta suggests using completely synthetic oils with characteristics equal or better than the ones prescribed in the following standards: –...
  • Page 25 Maintenance Remove the exhaust aluminium bulkhead as described in chapter C “Superstructures”. Place a container underneath the engine to collect the used oil. Remove the oil discharge plug (2). Recover the oil in an appropriate container. Do not scatter the drainage oil into the envi- ronment.
  • 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 – The crankcase. – Seepage on heat exchanger. If even the slightest leakage is found, over- haul the components as described in the Rivale 800 engine workshop manual (Part. Code 8000B6231). ENGINE COOLANT Check / top-up level ➝ At the pre-delivery, at the first 1000 kilometres and then every 6000 kilometres.
  • 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. Tightening torque of expansion vessel side cap: 8 N·m 8 N•m...
  • Page 29 Maintenance Engine coolant substitution Substitution→ every two years Before emptying the plant, first perform the following operations: remove the tank left side panel (see figures to the side); place a container under the engine to collect the used coolant; remove the right aluminium bulkhead (1) by loosening the 4 screws;...
  • Page 30 Maintenance Check the level of the coolant in the radiator once again, keeping the expansion vessel pipe closed with relevant pincers for rubber pipes. Should the level be too low, open the connection tube to the expansion vessel and let liquid flow out until the preset level.
  • Page 31 Maintenance ELECTRIC COOLING FAN Check → on pre-delivery and at the first 1000 kilometres and then every 6000 kilome- tres. To carry out the check on the functioning of the electric cooling fan, switch on the engine and heat it up. The electric fan must start up when the water temper- ature reaches the 5th or 6th notch on the dashboard.
  • Page 32 Maintenance After having removed the indicated components, the motorcycle is shown in the condition described by the photograph on side. Before proceeding with the various maintenance oper- ations, it is advisable to thoroughly wash and clean the motorcycle. Place the motorcycle (now without the components list- ed above and clean) on a workstation as indicated in the figure.
  • Page 33 Maintenance Disconnect the coil connector in three phases: a) move the “Secondary Lock” back. b) press the retainer clip. c) disconnect the connection. - 17 -...
  • Page 34 Complete removal of the engine head cover by tilting it towards the right side of the vehicle. To adjust the play of the tappets see the procedure in the Rivale 800 Engine Workshop Manual (Part. Code 8000B6231). - 18 -...
  • Page 35 Maintenance Remove the head cover gasket. Now remove the cover of the phonic wheel by acting on the eight screws. For further operations, see the Engine Workshop Manual (Part. Code 8000B6231). - 19 -...
  • Page 36 Every 12000 kilometres 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 Rivale 800 workshop engine manual (Part. Code 8000B6231). SPARK PLUGS Check / substitute ➝...
  • Page 37 Maintenance Heat Grade Check the heat grade of the spark plugs. Sparks: - NGK CR9 EIB-9 DO NOT use non-resistive spark plugs. Spark plug gap If appropriate (see Technical Data table), measure the spark gap with a thickness metre. Adjust the gap if necessary on the basis of the following information: Sparks Spark plug gap...
  • Page 38 Maintenance FUEL FILTERS Substitute → Every 50.000 km 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 • Saddle side panels • Fuel tank side panels •...
  • Page 39 Maintenance Check and replace the gasket Check the state of the sealing gasket (1) on the petrol 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. Using a worn gasket can cause petrol to leak from the tank and therefore pose the risk of the vehicle taking fire.
  • Page 40 Maintenance Remove the two worm-screws (3) and slide the ther- mistor rod out completely for replacement. Replace with a new component and re-mount following the removal operations in reverse order. Replacement the fuel filter Open the two metal band fasteners, one upper (1) and one lower (2) using the specific tool.
  • Page 41 Maintenance FUEL PUMP ASSEMBLY - 25 -...
  • Page 42 Maintenance Installing the fuel pump unit Position the fuel pump unit (1) inside the fuel tank. N.B.: apply a thin layer of silicon grease on the gas- kets before introducing them into the fuel pump unit. Screw on and tighten the 6 screws (2) through a repeated action.
  • Page 43 Maintenance Replacing fuel pipe in tank Substitute ➝ At least every three years The procedure to follow in the case of substitution of the feed tubing is as follows: Remove in this order: • Saddle • Saddle side panels • Fuel tank side panels •...
  • Page 44 Maintenance Replacing fuel pipe from throttle body Press the two stop buttons simultaneously and pull the pipe off. To reassemble the Airbox pipe, insert the fuel pipe in the fitting on the throttle body until you hear it lock. UTILISE ONLY NEW PARTS. To re-mount the tank pipe, press the two lateral green buttons at the same time and insert the pipe.
  • Page 45 RIVALE 800: Engine rpm 1400 ± 50 rpm Adaptive lambda check min -0.08...
  • Page 46 Maintenance Air Filter Check/substitute ➝ Every 6000 kilometres To access the air filter, the left tank side panel must be removed (1) as shown in the figure. Remove the left air conveyor (2) by removing the three screws. Remove the air filter (3) by sliding it out from the left air- box intake hole.
  • Page 47 Maintenance BRAKES Check the levels of fluid in the systems➝ At pre-delivery, at first 1000 kilo- metres and then every 6000 kilometres. Check for leakages➝ At pre-delivery, at first 1000 kilo- metres and then every 6000 kilometres. Substitute fluid➝ Every 24000 kilometres or at least every two years.
  • Page 48 Maintenance Add brake fluid until the correct level is reached in the chamber. Recommended brake fluid: AGIP Brake 4 Do not use brake fluid that comes from old containers, has already been used or does not come from a sealed container. Do not use brake fluid that is left over from previ- ous maintenance or stored for long peri- ods.
  • Page 49 Maintenance Checking the level of the rear brake fluid No parts of the vehicle need to be removed from the 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 and take...
  • Page 50 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 51 Maintenance Before closing the tank make sure its parts are intact. 8÷10 N•m Secure the rear brake fluid tank to the plate and then to the frame plate applying the fluid thread lock on the threads of the fixing screw and the tightening torque indicated: Torque pressure: 8 ÷...
  • Page 52 Maintenance BRAKE / CLUTCH / GEARCHANGE COMMANDS CHECK It is possible to adjust the position of the front brake lever, of the clutch and of the gear. Such adjustments have been created to optimise the grip and the move- ment of the commands with regards to the needs of the motorcyclist.
  • Page 53 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 54 Maintenance Adjusting the gear lever To adjust the gear lever it is necessary to: 1) Remove guard (1) by removing the three screws (2). 2) Slacken the two counter nuts (3) (rh thread) and (4) (lh thread). 3) Screw/unscrew by hand the gearbox transmission rod (5) until the lever reaches the desired position.
  • Page 55 Maintenance BRAKE PADS Wear check / substitute ➝ At the first 1000 kilo- metres and then every 6000 kilometres Check the condition and thickness of the brake pads on the calipers. Front brake caliper Rear brake caliper Measure the thickness of the pad linings. If the thick- ness of the linings is equal to or less than the wear limit shown below, replace the pads as described in chapter H “Brakes”.
  • Page 56 Maintenance LOCKS Check ➝ At the pre-delivery, at the first 1000 kilometres and then every 6000 kilo- metres. Ignition/steering block switch This switch has 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 57 Maintenance “LOCK” position Turn the handlebar left or right. Press the key down and rotate it to the “LOCK” position. All electrical circuits are disactivated and the steering is blocked. The key can be pulled out. “LOCK” position Left side Right side Fuel cap lock Lift up the anti-dust cover.
  • Page 58 Maintenance 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. If the fuel filler cap does not function (the cap does not close, the lock blocks, etc.) substitute it with a new one as described in chapter C “Bodywork”.
  • Page 59 Maintenance STEERING Check and adjust ➝ At the first 1000 kilometres and then every 12000 kilo- metres. Check the steering components regularly according to the above-mentioned intervals. If it is necessary to carry out adjustments, operate as described in chapter F “Suspension and wheels”. TRANSMISSION CHAIN Check ➝...
  • Page 60 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 61 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 62 Maintenance TYRES Check pressures➝ At the pre-delivery, at the first 1000 kilometres and then every 6000 kilometres. Check wear ➝ At the first 1000 kilometres and then every 6000 kilometres. If the tyre pressures are too high or too low, the ride is affected and tyre life duration is accentuated.
  • Page 63 Maintenance WHEELS Visual check ➝ At the first 1000 kilometres and then every 6000 kilometres (at least every tyre change). After having visually checked or following even light collision damage, it is necessary to check the planari- ty, the eccentricity and the ovalisation of the wheel. See the control procedures described in chapter F “Suspension and wheels”.
  • Page 64 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: - RIVALE 800: A = 160 mm The shock absorber contains gas under high pressure. Do not touch the shock absorber valve.
  • Page 65 Maintenance To remove the stand, follow these steps: - after having removed the kickstand switch, remove the screw (3); - remove screw (4). To refit the stand, follow the same steps in reverse order, taking care to tighten the screws to the pre- 40÷44 N•m scribed torque.
  • Page 66 Maintenance - using the specific tool, unhook the 2 springs (1); The substitution of the springs must be car- ried out utilising the appropriate tool. Before reattaching the springs, ensure that the stand can swing freely (with no friction or sticking). - remove the hinge plate (2);...
  • Page 67 Maintenance FRONT FORK Substitute oil ➝ every 24000 kilometres 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 of the forks, carry out the described operations in chap- ter F “Suspension and wheels”.
  • Page 68 Maintenance Mounting battery terminals Mount the positive terminal (+) on the relative pole of the battery as shown in figure. Turn the screw of the positive terminal and perform the prescribed tightening torque, using a torque wrench. Tightening torque: 7 ÷ 8 N·m When it has been mounted, place the protective cap on the positive pole (see figure).
  • Page 69 Maintenance Mount the negative terminal (-) on the relative pole of the battery as shown in figure. Turn the screw of the negative terminal and perform the prescribed tightening torque, using a torque wrench. Tightening torque: 7 ÷ 8 N·m Before tightening, make sure the cables face the right way.
  • Page 70 Maintenance INSTRUMENTS AND WARNING LIGHTS Warning lights Check ➝ At the pre-delivery, at the first 1000 kilo- Tachometer display metres and then every 6000 kilometres. The instrumentation check must be carried out com- pletely on all its functions as listed in the following list. If even one of the functions does not function correctly, consult chapter E “Electrical system”...
  • Page 71 Maintenance Multifunction display 11 Gear display It displays the currently engaged gear. The “0” digit stands for “neutral”. 12 Speedometer It displays the speed of the motorbike. It can be given in kilometres per hour (Km/h) or in miles per hour (Mph).
  • Page 72 Maintenance Selecting and setting the display functions Some of the main measurements of the instruments may be changed. The available options include: - Select an operating mode: “RUN” (Odometer) “SPEED LIMITER” “TC” (Traction control) “CHRONO” (Chronometer) “ABS” (Antilock braking system)* “QUICK SHIFT”...
  • Page 73 Maintenance “RUN” mode In addition to the speedometer, the display shows the 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 74 Maintenance “CHRONO” Mode This mode turns on the Chronometer and saves the 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°...
  • Page 75 Maintenance “CLOCK” Mode The present function enables to change the time (hours and minutes) reported on the dashboard. Trip reset To reset “TRIP 1” and “TRIP 2”, 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.
  • Page 76 Maintenance - Press the “OK” key for less than three seconds until the partial speedometer 2 function (“TRIP 2”) appears on the display. - By pressing the “OK” key for more than three sec- onds, the “TRIP 2” value will be reset to zero. - 60 -...
  • Page 77 Maintenance “SPEED LIMITER” mode When starting the engine, the “SPEED LIMITER” func- tion is disabled. In order to activate it, it is necessary to perform the following operations: - Press “SET” in order to access to “SPEED LIMITER” mode. The maximum speed value shown on the dis- play (equal to the current speed of the vehicle) starts blinking.
  • Page 78 Maintenance - If the “SPEED LIMITER” function has been enabled, when riding the vehicle the speed value shown on the odometer starts blinking when it reaches the set value of the maximum speed. “TC” Mode - Press “SET” in order to access to “TC” mode, then press “OK”...
  • Page 79 Maintenance Chronometer Lap time recording - Turn on the chronometer (“CHRONO” mode) to record the time taken to cover a lap. - Press the headlight button to start recording the time. The colon that separates the minutes from the sec- onds and from the tenths of a second will start blink- ing.
  • Page 80 Maintenance - If using the chronometer again, every time you press the headlight button, it records a time. The instrument can record up to100 consecutive times. When the time for the lap which has just concluded is displayed, the symbol “+” or “-” appears if the time recorded is respectively higher or lower than the time measured during the previous lap.
  • Page 81 Maintenance - 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” key to return to the “LAPS VIEW” mode and then to the following mode.
  • Page 82 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 83 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 84 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 85 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 86 Maintenance - Otherwise, by pressing “OK” while the caption is still blinking, “ABS OFF” appears on the display. - If you do not press any button, after three seconds the “ABS OFF” selection is confirmed; under this con- dition, the ABS system is deactivated. Press “SET” to exit the “ABS”...
  • Page 87 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 88 Maintenance How to select the mapping of the control unit On the Rivale 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 89 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 90 Maintenance - Press “OK” for more than three seconds; the new set- ting will be confirmed. The displayed caption stops flashing and after a few seconds the display returns to “GAS SENSITIVITY” mode. It is now possible to pro- ceed with the setting of the following parameter. - Maximum engine torque: Press “OK”...
  • Page 91 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 sequence: • “RAIN” • “SPORT” - Press “OK” for more than three seconds; the new set- ting will be confirmed.
  • Page 92 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 sequence: •...
  • Page 93 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 94 Maintenance - Press “OK” for more than three seconds; the new set- ting will be confirmed. The displayed caption stops flashing and after a few seconds the display returns to “ENGINE RESPONSE” mode - Engine RPM limiter: Press “OK” for less than three seconds until “RPM LIMITER”...
  • Page 95 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 sequence: • “NORMAL” • “SPORT” - Press “OK” for more than three seconds; the new set- ting will be confirmed.
  • Page 96 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 97 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 98 Maintenance “SERVICE” Mode This operating mode displays the mileage range with respect to expiration of the next scheduled mainte- nance. NOTE When the mileage range upon maintenance servicing is less than 1000 km, its relative value automatically appears after the start-up screen of the motorcycle. “UNIT CHANGE”...
  • Page 99 Maintenance - Press the "OK " button for less than three seconds until the message “MV SERVICE KM” is displayed. - 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.
  • Page 100 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 101 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. LIGHTS Check ➝ At the pre-delivery, at the first 1000 kilometres and then every 6000 kilo- metres.
  • Page 102 Maintenance - Remove the screws on the left side. - Open the left clamp and rotate the headlight assem- bly as shown in the picture. - Remove the protection cover. - 86 -...
  • Page 103 Maintenance - Release the retaining clips. - Slide out the bulb. CAUTION - Do not touch the bulb glass with bare hands. If you do, clean the bulb with an oil-free solvent. - Unhook the connector. - 87 -...
  • Page 104 Maintenance - Replace the light bulb. - Attach the light bulb to the connector. - Reinsert the light bulb. - Reconnect the retaining clips. - Reinsert the protection cover. - Remount the headlight assembly on the motorcycle going in reverse order to the disassembly. Before tightening the fastening screws, push the headlight assembly upwards until it is in abutment as shown in the picture.
  • Page 105 Maintenance - To replace the fuse, you must swap the recharge fuse with the spare fuse. WARNING Never replace a fuse with a rating other than that prescribed, in order to avoid damage to the electrical equipment of the motorcycle which could lead to a fire.
  • Page 106 Maintenance - Replace the blown fuse and refit the cover. - 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 107 Maintenance FRONT HEADLAMP Check adjustment ➝ At every variation of the motorcycle set-up. 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 108 Maintenance - 92 -...
  • Page 109 Superstructures SECTION Revision 0 - 1 -...
  • Page 110 Superstructures SUMMARY FAIRINGS ..............................PAGE 3 REMOVING FRONT MUDGUARD .......................PAGE 4 FRONT HEADLIGHT COVER DISASSEMBLY ...................PAGE 4 HEADLIGHT SUPPORT DISASSEMBLY....................PAGE 6 DASHBOARD DISASSEMBLY ......................PAGE 7 REMOVING HANDLEBAR ........................PAGE 8 FUEL TANK ...............................PAGE 12 DISASSEMBLY OF NUMBER CARRIER SIDE PANELS AND SEAT RAIL SIDE PANELS ....PAGE 13 REMOVING FUEL TANK ........................PAGE 16 RADIATOR SIDE PANELS........................PAGE 20 INTAKE AIR SYSTEM - AIRBOX ......................PAGE 23...
  • Page 111 Superstructures FAIRINGS - 3 -...
  • Page 112 Superstructures REMOVING FRONT MUDGUARD Remove the six screws of the mudguard as shown in figure (the screws are mounted with a socket key). Remove the front brake hoses from the clamps mount- ed on the mudguard. Pull off the mudguard towards the front. FRONT HEADLIGHT COVER DISASSEMBLY Remove the four fixing screws from the headlight, two frontal (1) and two lateral (2).
  • Page 113 Superstructures Slide the headlight cover out. Remove the four fixing screws (1) of the headlight to the support. Remove the headlight connector (2) using a screwdriv- - 5 -...
  • Page 114 Superstructures HEADLIGHT SUPPORT DISASSEMBLY Remove the four fixing screws from the support (two per part). Open the light support hatches. Extract the headlight support. - 6 -...
  • Page 115 Superstructures DASHBOARD DISASSEMBLY Loosen the central fixing screw with relative washer. Slide out the rubber hood (1) and release the connec- tor (2) using a screwdriver. Release the dashboard from the relevant rubber pads on the support. - 7 -...
  • Page 116 Superstructures REMOVING HANDLEBAR Before performing this operation, first disassemble the front low beam, the dashboard and the low beam sup- port (optional) as described in the previous pages. Disconnect the six (seven for vehicles with ABS) main connectors: - n°4 situated in the front area of the vehicle; - on vehicles with ABS, it is also necessary to discon- nect the front wheel speed sensor connector.
  • Page 117 Superstructures - disconnect the 2 manifolds situated on the right and left sides under the handlebar (direction indicators). Loosen the clutch on the handlebar side and engine side. Slide out the clutch transmission cable from both sides. - 9 -...
  • Page 118 Superstructures Remove the front brake pump by operating on the screw (1) and open the hatch (2). Slide the pump unit from the handlebar. Disconnect the front brake stop light switch connectors (3). - 10 -...
  • Page 119 Superstructures Loosen the four fixing screws (4) of the handlebar stand (two screws per part) and remove the stand. Remove the handlebar (5). When reassembling the handlebar, pay attention to the correct positioning of the U- bolts respect to the handlebar. Refer to the timing signs on the sides of the handlebar.
  • Page 120 Superstructures FUEL TANK - 12 -...
  • Page 121 Superstructures Before removing the fuel tank, the driver's seat must be removed beforehand. DISASSEMBLY OF NUMBER CARRIER SIDE PAN- ELS AND SEAT RAIL SIDE PANELS Remove the two upper screws (1) of the number carri- er side panel (2) and one lower screw (3). Disconnect the tail light connector.
  • Page 122 Superstructures Release the side panel from the pin and extract it. Remove the five screws of the seat rail side panel. - n°4 lateral (1); - n°1 lower (2); - 14 -...
  • Page 123 Superstructures Release the tank side panel by loosening the five screws. Remove the side panel as shown in the figure. - 15 -...
  • Page 124 Superstructures REMOVING FUEL TANK Loosen and remove the four fixing screws from the tank upper plate and remove the plate. Unscrew and remove the two front screws (1) fasten- ing the fuel tank to the frame. Two persons are required for the following operation. Lift the fuel tank upwards.
  • Page 125 Superstructures Disconnect the fuel pipe on the left side, pressing both green buttons and pulling the quick coupling down- wards. Disconnect the electric connection on the pump. Disconnect the overflow pipe on the bottom rear part. To make disengaging fittings from the fuel NOTE pump flange easier, two operators are rec- ommended, one to support the tank and...
  • Page 126 Superstructures Removal of fuel tank cap Insert the key supplied with the motorcycle in the fuel cap lock, turn it clockwise and open the cap. Unscrew and remove the three screws (1) at 120° (the other three screws are fake). 4 ÷...
  • Page 127 Superstructures Remove the cap (3). Fuel tank cap fixing screws tightening torque: - n°3 external screws: 4 ÷ 5 N·m - Internal safety screw: 4 ÷ 5 N·m - Apply Loctite 243 and take it into position. - 19 -...
  • Page 128 Superstructures RADIATOR SIDE PANELS - 20 -...
  • Page 129 Superstructures Remove the three fixing screws (1) from the aluminium bulkhead. Remove the bulkhead (2). Remove the three fixing screws (3) of the plastic sup- port to the frame and the radiator and remove the sup- port. - 21 -...
  • Page 130 Superstructures For USA version vehicles, insert the two spac- NOTE ers (4) shown in the photo (one per side). - 22 -...
  • Page 131 Superstructures INTAKE AIR SYSTEM - AIRBOX - 23 -...
  • Page 132 Superstructures REMOVING AIRBOX Before removing the Airbox, you must first remove the fuel tank as described in this chapter. Disconnect the air temperature sensor connector. Disconnect the air pressure sensor and engine phase connector. - 24 -...
  • Page 133 Superstructures Remove the right and left air inlet duct, unscrewing three screws on the side. Remove the air filter. AIRBOX REMOVAL Remove the nine fixing screws on the Airbox cover. - 25 -...
  • Page 134 Superstructures Remove the two front fixing screws. Remove the rear fixing screw. Disconnect the blow-by pipe. - 26 -...
  • Page 135 Superstructures Lift the lower airbox. When reassembling it, perform the same operations carried out during disassembly. 2 front fixing screws tightening torque: 10 N·m 10 N•m Rear fixing screw tightening torque: 8 N·m 8 N•m - 27 -...
  • Page 136 Superstructures REAR TAIL - 28 -...
  • Page 137 Superstructures LOWER BULKHEAD AND TAIL LIGHT - 29 -...
  • Page 138 Superstructures To remove the driver's seat, the fuel tank side panels, the side number holder and the underseat panels, refer to the paragraph " Fuel tank" in this chapter. TAIL TIDY DISASSEMBLY Remove the four upper screws and the lower screw (1).
  • Page 139 Superstructures FOOT PEG SUPPORT DISASSEMBLY Remove the two screws (1) and slide the foot peg sup- port out. DISASSEMBLY OF THE FRAME LOWER BULK- HEAD Remove the six fixing screws of the frame bulkhead (three per side). Slide the bulkhead from the lower part of the frame. - 31 -...
  • Page 140 Superstructures DISASSEMBLY OF THE GLOVE COMPARTMENT BULKHEAD Remove the fixing screw (1) and remove the bulkhead (2). REMOVING NUMBER PLATE SUPPORT Loosen the left screw (1) of the hub. Turn the wheel manually and insert the spanner in the space between the spokes. - 32 -...
  • Page 141 Superstructures Loosen the right screw (2) on the hub. Continue to loosen the right screw manually, without removing it. Remove the left screw. To facilitate sliding out the right screw, it is good prac- tice to remove the rear wheel as described in Chapter F “Suspensions and wheels”.
  • Page 142 Superstructures Loosen and remove the screw (3) of the rear third point attachment. Remove the switch cover (4) by loosening the two M5 screws (5). Slide the right screw of the hub out (2), supporting it with the other hand. - 34 -...
  • Page 143 Superstructures Rest the support on the surface. Disconnect the three connectors (6) (to for the indica- tors and one for the number plate light) with the aid of a small screwdriver. The support is disassembled at this point. - 35 -...
  • Page 144 Superstructures DISASSEMBLY OF THE COMPLETE MUDGUARD NUMBER PLATE CARRIER UNIT Remove the two small plates that contain the electric wiring. Loosen the two screws (1) on the largest plate (2). Loosen the screw (3) on the smallest plate (4). Remove the arm by taking out the five screws, four at the bottom (5) and one at the top (6).
  • Page 145 Superstructures Disassemble the number plate by removing the four screws (7) with wrench and 2.5 screwdriver, as shown in the figure. Loosen the two screws on the slide (8). Push the slide upwards in a way to release the four M6 fixing screws (9) of the number plate carrier on the mudguard.
  • Page 146 Superstructures Loosen the four fixing screws (10) attaching the mud- guard to the internal support and tilt the mudguard without internal support. Remove the internal support (11) from the mudguard. Remove the two small plates (12) holding the electric cables. - 38 -...
  • Page 147 Superstructures Cut the heat-shrinking material (13) on the electric cables. Release the number plate carrier unit from the mud- guard. Loosen the two screws (14) and remove the number plate light. Loosen the two nuts (15) and remove the retro reflector. - 39 -...
  • Page 148 Superstructures Remove the six screws (16) with rear indicators fixing washer. Cut the band fastener (17) joining the electric cables. At this point, the indicators will be as in the figure (com- plete with spacers and rubber pads). To re-assemble the unit, proceed in reverse order, fol- lowing the layout (given below), which indicates the correct tightening torques and fixing where the thread- locker is to be applied.
  • Page 149 Superstructures - 41 -...
  • Page 150 Superstructures TAIL LIGHT DISASSEMBLY Disassemble the number carrier side panel from the rear frame. To remove the tail light, operate on the three screws (1), loosening them and releasing the tail light. DISASSEMBLY OF EXHAUST GUARDS - 42 -...
  • Page 151 Superstructures Remove the eight screws (1) (4 per part as shown in the photo) and slide the two bulkheads downwards. - 43 -...
  • Page 152 Superstructures - 44 -...
  • Page 153 Air intake injection system SECTION Revision 0 - 1 -...
  • Page 154 Air intake injection system SUMMARY INJECTION SYSTEM TECHNICAL CHARACTERISTICS ........PAGE 3 INJECTION TIME COMPENSATION (VOLUME) .
  • Page 155 Air intake injection system INJECTION SYSTEM TECHNICAL CHARACTERISTICS INJECTION TIME (INJECTION VOLUME) The factors for the determination of the injection time are the basic injection time that is calculated on the basis of the torque request, 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 156 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 follow- ing 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 157 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 158 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 159 Air intake injection system FUEL PUMP CONTROL SYSTEM When the ignition switch is turned to the ON position, the fuel pump motor is started by the current supplied by 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 160 Air intake injection system The ECU (1) is situated under the tank behind the bat- tery. 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 161 Air intake injection system 2 INTAKE AIR TEMPERATURE SENSOR The temperature of the intake air is found by con- 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 162 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 163 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 164 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) located behind the right fairing of the motorcycle, identified by a ring marked with "I" located on the cable harness. - 12 -...
  • Page 165 Air intake injection system Ignition coils The ignition coils are of the top plug type (they are assembled directly on the spark plugs. This avoids the use of the HT leads and enhance the overall system reliability.. - 13 -...
  • Page 166 Air intake injection system DIAGNOSTICS SYSTEM Ignition and injection system diagnostics For the diagnosis of the ignition and injection system a 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 167 Air intake injection system Eldor power unit fault codes (with TEXA diagnostic software) Component/Function [Fault Takeover Cause Fault detection rules [DTC Code] Symptom] Over Short circuit to CONDITION FOR DETECTION: Always maximum Supply volta- PO, Ck, Er, Vr DETECTION: It is recognized a fault if the Exhaust Threshold ge or Vehicle Exhaust Valve sensor Diagnosis...
  • Page 168 Air intake injection system Eldor power unit fault codes (with TEXA diagnostic software) Component/Function [Fault Takeover Cause Fault detection rules [DTC Code] Symptom] Open Circuit Over CONDITION FOR DETECTION: Always or Short circuit maximum PO, Ck, Er, Vr to Supply vol- DETECTION: It is recognized a fault if the sensor Threshold tage or...
  • Page 169 Air intake injection system Eldor power unit fault codes (with TEXA diagnostic software) Component/Function [Fault Takeover Cause Fault detection rules [DTC Code] Symptom] CONDITION FOR DETECTION: If Rpm >0 and Over Short circuit to Lambda Sensor 1 heater diagnosis THINFVBATDDIAG< Vbattery < HSUPVBATDDIAG maximum Supply volta- P0135...
  • Page 170 Air intake injection system Eldor power unit fault codes (with TEXA diagnostic software) Component/Function [Fault Takeover Cause Fault detection rules [DTC Code] Symptom] CONDITION FOR DETECTION: Always Signal is not Plausibility DETECTION: It is recognized a fault if Er, Vr plausible or [1000] THLOW2GASSWDIA<VGasIDLSw<THUPP1GAS-...
  • Page 171 Air intake injection system Eldor power unit fault codes (with TEXA diagnostic software) Component/Function [Fault Takeover Cause Fault detection rules [DTC Code] Symptom] Over Short circuit to CONDITION FOR DETECTION: If Rpm >0 and maximum Supply volta- THINFVBATDDIAG< Vbattery < HSUPVBATDDIAG Ck, Er, Vr Threshold ge or Vehicle...
  • Page 172 Air intake injection system Eldor power unit fault codes (with TEXA diagnostic software) Component/Function [Fault Takeover Cause Fault detection rules [DTC Code] Symptom] CPU diagnosis CONDITION FOR DETECTION: Always Plausibility System error P0606 PO, Ck, Er, Vr [1000] DETECTION: It is recognized a fault if a reset [0606 hex] occurs Hardware Thermal Shut Down...
  • Page 173 Air intake injection system Eldor power unit fault codes (with TEXA diagnostic software) Component/Function [Fault Takeover Cause Fault detection rules [DTC Code] Symptom] CONDITION FOR DETECTION: Rpm > THRPM- GEARDIAG DETECTION: It is recognized a fault if Over Short circuit to VGearPos>VGEARPOSMAX for a time >...
  • Page 174 Air intake injection system Eldor power unit fault codes (with TEXA diagnostic software) Component/Function [Fault Takeover Cause Fault detection rules [DTC Code] Symptom] ION 1 signal diagnosis (StPhase) P1301 [1301 hex] ION 2 signal diagnosis (StPhase) P1302 CONDITION FOR DETECTION: If Rpm >0 Signal is not [1302 hex] Plausibility...
  • Page 175 Air intake injection system Eldor power unit fault codes (with TEXA diagnostic software) Component/Function [Fault Takeover Cause Fault detection rules [DTC Code] Symptom] Rear stop light command CONDITION FOR DETECTION: If Signal is not diagnosis (HSD) THINFVBATDDIAG< Vbattery < HSUPVBATDDIAG Plausibility plausible or PO, Ck, Er, Vr...
  • Page 176 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 177 Air intake injection system POSITIONS OF ENGINE-CONTROL SYSTEM PARTS - 25 -...
  • Page 178 Air intake injection system INJECTION SYSTEM ELECTRICAL DIAGRAM SOLENOID STARTER BATTERY FUEL PUMP, INJECTOR FUSE COIL FUSE FUEL PUMP - COILS - INJECTORS RELAY MAIN RELAY CLUTCH SWITCH - 26 -...
  • Page 179 Air intake injection system Engine control unit pinout, MV Agusta Rivale 800 Connector Vehicle Engine Pin name Description of associated function Type Pin n° Pin n° IN_REL+ INPUT CRANKSHAFT POSITION SENSOR + VRS interface IN_REL- INPUT CRANKSHAFT POSITION SENSOR -...
  • Page 180 Air intake injection system Engine control unit pinout, MV Agusta Rivale 800 Connector Vehicle Engine Pin name Description of associated function Type Pin n° Pin n° OUT_LOW_BEAM OUTPUT LOW BEAM LIGHT RELAY MANAGEMENT CONTROL Low side OUT_FAN_RELAY_1 OUTPUT ELECTRIC FAN RELAY MANAGEMENT CONTROL 1...
  • Page 181 Electrical system SECTION Revision 0 - 1 -...
  • Page 182 Electrical system - 2 -...
  • Page 183: Electrical System

    Electrical system CONNECTORS • When a connector is connected, check that it clicks into position. • Check the connector for corrosion, dirt or a broken cover. CLICK COUPLINGS CLICK • Block couplings – ensure that the block is released before disconnecting it to push it completely home when connecting it.
  • Page 184 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 185 Electrical system ELECTRICAL DIAGRAM RIVALE 800 F2 F3 F4 F5 F6 F7 F1 F2 F3 16 18 6 5 4 5 6 7 8 Br-Bk R-Bk Br-Y Br-Bk V-Gr O-Bk R-Gr Gr-Bk B-Bk Br-W Br-P Br-B Gr-O B-Bk Gr-Bk Gr-P...
  • Page 186 Electrical system Parts list Parts list Ref. Description Ref. Description Key switch Power unit Safety and front brake switch Plate light Front turn indicator, right hand Rear turn indicator, right hand Front light Rear turn indicator, left hand Intermittence Dashboard Power relay Air pressure sensor Brake light - Stop...
  • Page 187 Electrical system ELECTRICAL DIAGRAM RIVALE 800 (VERSION WITH ABS) F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F1 F2 F3 16 18 6 5 4 5 6 7 8 Br-Bk R-Bk Br-Y V-Gr Br-Bk O-Bk R-Gr Gr-Bk B-Bk...
  • Page 188 Electrical system Parts list Parts list Ref. Description Ref. Description Key switch Power unit Safety and front brake switch Plate light Front turn indicator, right hand Rear turn indicator, right hand Front light Rear turn indicator, left hand Intermittence Dashboard Power relay Air pressure sensor Brake light - Stop...
  • Page 189 Electrical system BATTERY The battery mounted on this motorcycle is a sealed battery therefore no maintenance is required. The following battery is used: BS BTZ 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 190 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 191 Electrical system REMOVAL OF THE BATTERY To carry out this operation it is necessary to remove the seat, the sides and the tank as described in sec. C (Superstructures). 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 192 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- board.
  • Page 193 Electrical system A list of possible problems that could occur when the warning light is switched on. SI RISCONTRANO PROBLEMI RIPRISTINARE O PULIRE LA SPIA ANCORA ACCESA RESTORE OR CLEAN CON- WARNING LIGHT STILL ON PROBLEMS OCCUR SULLA CONNESSIONE CONNESSIONE NECTION WITH CONNECTION POSITIVO SU BATTERIA...
  • Page 194 Electrical system BATTERY EFFICIENCY CHECK Battery current loss check • Remove the seat as described in chapter C “Superstructures”. • Turn the ignition switch to the “OFF” position. • Disconnect the cable from the negative (-) pole of the battery. •...
  • Page 195 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. When carrying out this check, ensure that NOTE the battery is fully charged.
  • Page 196 Electrical system SOLENOID STARTER BATTERY FUEL PUMP, INJECTOR FUSE COIL FUSE FUEL PUMP - COILS - INJECTORS RELAY MAIN RELAY CLUTCH SWITCH - 16 -...
  • Page 197 Electrical system SOLENOID STARTER BATTERY FUEL PUMP, INJECTOR FUSE COIL FUSE FUEL PUMP - COILS - INJECTORS RELAY MAIN RELAY CLUTCH SWITCH - 17 -...
  • Page 198 Electrical system SOLENOID STARTER BATTERY FUEL PUMP, INJECTOR FUSE COIL FUSE FUEL PUMP - COILS - INJECTORS RELAY MAIN RELAY CLUTCH SWITCH - 18 -...
  • Page 199 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 200 Electrical system STARTER MOTOR REMOVAL • Remove fuel tank (see chapter “Superstructures”). • Remove the seat lock plate (1). • Remove the blow-by tube. • Disconnect the cable of the starter motor. • Remove the two fixing screws (2) of the starter motor.
  • Page 201 Electrical system STARTER MOTOR CHECK If a fault has been diagnosed in the starter motor, it is necessary to proceed as follows with the check: • Connect a tester between earth and the starter motor terminal. • Check that there is continuity between the positive pole and the engine earth.
  • Page 202 Electrical system • Disconnect the cables (1) 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...
  • Page 203 Electrical system GEARCHANGE POSITION SWITCH The connector (1) of the gear position sensor is locat- ed on the left beneath the tank. The check is made using the diagnostics instrument. Whenever the instrument should detect an anomaly, with the key in ON that there is a voltage of 5 V between pins 1 and 3 on the plant side of the gear position sensor con- nector.
  • Page 204 Battery recharge Solenoid starter hazard. Battery recharge supply Solenoid starter FUSE RIVALE 800 ABS The fuses are found under the saddle in front of the battery compartment. Remove the saddle. - 24 -...
  • Page 205 Electrical system The service fuses are numbered from 1 to 10 starting ABS version from the left the four reserve fuses are found in the Fuse Amp. (A) Application Position underlying part. Fuel pump - Coils Fuse Box The recharge fuse F11 and the reserve fuse F12 are Lambda sensor - Injectors Fuse Box found on the solenoid starter.
  • Page 206 Electrical system Check the resistance between the electrode and the screw cap of the spark plug as shown in the figure. Permitted resistance: 4,5 ÷ 5,5 KΩ Carry out the test on all the spark plugs. Do not use non-resistive spark plugs. MAIN RELAY The main relay is under the right side panel.
  • Page 207 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 208 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 209 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 210 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 211 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 212 Electrical system KEY SWITCH Whenever the dashboard, with the switch on the ON 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 213 RIVALE 800 • Check the conditions of the fuse in position 5 on the fuse box. RIVALE 800 ABS • The vehicles with ABS are checked using the diag- nostics tool. If the fuse in question is in good condition, proceed...
  • Page 214 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 215 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 under the right side panel of the motorcycle. LICENCE PLATE LIGHT If the number plate light does not work, check the integrity of fuse 3 in the fuse box;...
  • Page 216 Electrical system • Remove the two fixing screws and the number plate bulb that is to be replaced. Re-assemble operating in reverse order with respect to disassembly. REAR TAIL LIGHTS AND BRAKE LIGHTS The stop lights are controlled by the stop lights control unit positioned under the right side panel every time the key in the ignition block is put in the ON position.
  • Page 217 Electrical system Now check the continuity between the Green/Black cable of the right lights connector and the Green/Black cable of the control unit connector. Operate in the same way on the left side between the Pink/Blue cable of the lights connector and the Pink/Blue cable of the control unit connector.
  • Page 218 Electrical system Remove the protection by operating on the three screws (1). Remove the indicator by operating on the screw (2) and on the two screws (3). REAR TURN INDICATOR LIGHTS If they do not work, the controls to be performed are identical to those of the front indicators.
  • Page 219 Electrical system Remove the three screws (1) proceed with the replace- ment of the turn signal. Re-assemble operating in reverse order with respect to disassembly. COOLING FAN SYSTEM If there is a fault in the functioning of the cooling fan, proceed with the following check: •...
  • Page 220 Electrical system HORN A fault in the horn system should be checked at various points: • Check the condition of fuse 6 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 221 Electrical system REPLACEMENT OF THE ABS UNIT (Present only on model Rivale ABS) When replacing the ABS unit, it is necessary to perform the operations described as follows. • Remove the following components as described in chapters C - “Superstructures” and G - “Frame”: - Saddle - Fuel tank side panels - Number carrier side panels...
  • Page 222 Electrical system • Remove the upper fixing screw (2) of the ABS unit support. • Lower the front part of the undersaddle fairing and remove the two fixing screws (3) of the ABS unit support. • Lean the electric devices support over the rear frame and extract the ABS unit with its support, by pulling it towards the rear side of the motorcycle.
  • Page 223 Electrical system • Remove the two screws (4) fixing the ABS unit to its support. 8 ÷ 10 N·m • Remove the ABS unit. • Assemble the new ABS unit on the support. • Insert the two fixing screws of the ABS unit and tigh- ten them to the prescribed torque.
  • Page 224 Electrical system ABS unit activation Once the assembling operations have been comple- ted, it is necessary to perform the activation procedure of the new ABS unit by using the TEXA diagnosis software as described below. • Start from the “Self-diagnosis” display, then press the button shown in the picture to enter the “Adjustments”...
  • Page 225 Electrical system • Once you have identified the model of the vehicle, press the “CONFIRM” button in order to proceed with the activation of the ABS unit. • If you selected the correct vehicle model, when the activation procedure has been completed, a confir- mation message appears in the lower portion of the display.
  • Page 226 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 - 46 -...
  • Page 227 Electrical system POSITIONING OF ELECTRICAL SYSTEM WIRE CLAMPS RIVALE 800 LIST OF FASTENING CLAMPS FOR RIVALE 800 ELECTRICAL SYSTEM CABLES Code Qty. Length Name 800092248 L = 82 mm Rubber clamp L 82 800092247 11 * L = 62 mm...
  • Page 228 Electrical system Note: Pass the clutch cable over Note: Place the connector Code Code the electric wiring vertically Position sheath at Sheath 100 mm from the Code node O band fasteners Code Code Code Note: Place the wiring behind the frame cross-member Code - 48 -...
  • Page 229 Electrical system Code Note: attention to the cor- Code rect passage of the On/Off cable Note: attention to Note: attention to the cor- the correct passage rect passage of the air of the vent pipe temp. sensor cable Code Note: Pay attention to the correct passage of the plug-top connectors cables - 49 -...
  • Page 230 Electrical system Note: Avoid contact between brake pipe and dashboard Note: Pay attention to the correct passage of Note: Position the band fasten- Code the dashboard cable er in correspondence with the outside the headlight pint nearest to the dashboard (updated support version)
  • Page 231 Electrical system Note: Avoid contact between Note: Pass the cables the brake pipe and dashboard inside the plate/Keep the – Position the band fastener in cable out of the micro correspondence with the point switch nearest to the dashboard Code Code Note: Avoid contact between the clutch pipe...
  • Page 232 Electrical system Note: On-Off connec- Position sheath at tor position (hidden 50 mm from the behind the frame node F tube) (See Fig. Code Sheath Code band fasteners (See Fig. 05) Code Code Code L=25 (contains standing cable Code and temperature (contains the generator sensor cable) connector –...
  • Page 233 Electrical system Note: Position fuel pump connector (hidden behind frame tube – only for wiring up to Rev.B) Note: Position fuel pump connector (for Code wiring from Rev.C) L=62 (only for wiring up to Rev.B) Code Code L=25 (for EAS ver- sion only) Code Note: EAS con-...
  • Page 234 Electrical system Code Note: Pay attention to the correct pas- Code sage of the cables Lambda probe connector Side stand cable con- nector Pay attention to the correct direction of assembly of the starter motor connector Code - 54 -...
  • Page 235 Electrical system Code (contains number plate carrier lights wiring + speed sensor cable + rear brake pipe) Code Note: Pay attention to the correct positioning of the connectors on the cover Code - 55 -...
  • Page 236 Electrical system Code Code Code Code Code Code - 56 -...
  • Page 237 Electrical system Ignition switch Code cable (contains rear light + recharge + diagnosis cables) Battery (-) pole cable Code (contains control unit cables and fuse box cables) Note: Pay attention to the correct passage of Code the of the battery (+) pole/contactor cable L=25 (contains N°2 earth cables) Code...
  • Page 238 Electrical system Indicator inter- Dashboard mittence diagnostics Position band fastener in correspondence of the clip nut Code Buffer Code Code Note: Pay attention to the correct passage of Note: Pay attention to the fall sensor cable the correct passage of the seat lock cable Note: Pay attention to the correct passage of...
  • Page 239 Electrical system Code Code Code Code Sheaths Code band fasteners - 59 -...
  • Page 240 200 mm from the sectioning junction on the connecting tubes to the brake calipers (see fig. 01). For the position of the clamps for fastening the Rivale 800 ABS system hoses, refer to the layout shown below (see figs. 02-11). Code Code...
  • Page 241 Electrical system Note: Recovery of exceed- ing cabling as shown Code Code Code Note: Position of the bifurcation of the sensor/ABS- hose cable Code Keep the clutch cable over the ABS hoses - Pay atten- tion not to twist the cables together - 61 -...
  • Page 242 Electrical system Orient the head of the clamp as much as possible toward the front of the bike Sheaths Code band fasteners Pass the ABS hoses on the right side of the tank vent pipes Sheaths Code band fasteners Nr.1 screw cap (Code 8000B9342) on stem fork of the rear damper - 62 -...
  • Page 243 Electrical system Note: Keep the rear replaces the clamp brake hose behind L = 25 fitted on the other hoses motorcycles without ABS system - see page 51 Code Code Code Code Note: Pay attention to the Note: Pay attention to the correct positioning of the correct positioning of the ABS rear brake hoses...
  • Page 244 Electrical system On completion of the positioning and clamping of pipes, fix the terminals to the ABS module mounted on the holder on the rear subframe as shown in Figure 12. Tighten the couplings of the terminals to a torque of 18 Nm Rear brake Front brake caliper hose...
  • Page 245 Suspension and wheels SECTION Revision 0 - 1 -...
  • Page 246 Suspension and wheels SUMMARY FRONT WHEEL ..............PAGE 3 FRONT FORKS .
  • Page 247: Front Wheel

    Suspension and wheels FRONT WHEEL N·m 16 ÷ 18 Torque Kg·m pressure ft·lb Operation Description Rivale 800 FRONT WHEEL Material Aluminium alloy Dimensions 3.50” x 17” FRONT TYRE Dimensions 120/70-ZR 17 M/C (58 W) TL Brand and type PIRELLI - Diablo Rosso Corsa Front tyre pressure: 2.3 bar (33 psi)
  • Page 248 Suspension and wheels Before proceeding with the removal and overhaul of the components relative to the front suspension, it is advisable to remove beforehand the front mudguard as described in detail in chapter C “Bodywork”. Place the motorcycle on the rear stand. Special tool No.
  • Page 249 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 250 Suspension and wheels Front wheel bearing check With the wheel spindle still mounted to the wheel, 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 251 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. Operate in the same way on both bearings. NOTE Check that the ends of the aluminium spacer and the seats of the bearings on the wheels are not scored or marked.
  • Page 252 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 253 Suspension and wheels Wheel spindle check Place the wheel spindle on two v-prisms on a flat sur- face. Utilising a dial gauge, check that the eccen- tricity in the central part does not exceed 0.05 mm. Wheel assembly If the front tyre is substituted, before assem- bling the wheel it is necessary to balance the wheel following the indications in page 68.
  • Page 254: Front Fork

    22 ÷ 24 Torque Kg·m pressure ft·lb Operation Description Rivale 800 FRONT SUSPENSION Type “Upside down” telescopic hydraulic fork with external and separated adjustment of rebound and compression damping and of spring preload Ø stems (mm) Telescopic movement (mm) - 10 -...
  • Page 255 Suspension and wheels FRONT FORK OVERHAUL Remove the front wheel as described in the paragraph ”Front wheel removal” of this Chapter. Support the motorcycle by the rear stand with special tool. Special tool No. 8000B9312 Stem removal Loosen the 2 screws (2) from the steering base and the screw (3) from the steering head.
  • Page 256 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 257 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. - 13 -...
  • Page 258 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 259 Suspension and wheels Lower dust cap (1), taking care not to damage the seat on the sheath. Remove the retaining ring (2) with a screwdriver, tak- ing care to not scratch the stem. Extract the sleeve from the stem by repeated blows at the end.
  • Page 260 Measure the length of the spring and compare with the following values: - Rivale 800: 330 mm To replace the bushings inside the sleeve, operate using the required tool in accordance with the method described in the diagram.
  • Page 261 Suspension and wheels Mount the rod in the lining taking the bushing into the seat with the respective washer; use the specific tool. Mount the oil retainer using the same technique. Special tool No. 8000B6785 Insert the clamping ring (1) in place. Then, put the dust seal in (2) by hand.
  • Page 262 Tighten at 35 N•m. While holding the sheath in an upright position, insert the spring press spacer; pour in the following oil quan- tities: - Rivale 800: 470 cc (*) (*): approximate quantity calculated in relation to the actual maintenance level.
  • Page 263 Suspension and wheels Lift the plunger and manually turn the counternut (1) in to the end of the threaded portion. Put the spring in by holding the pump rod in an extend- ed position outside of the sleeve. Insert the 13 mm wrench under the pump nut (1) to stop the rod from falling out.
  • Page 264 Suspension and wheels 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 Insert and screw in the complete cap (1) on the fork slider at the required torque.
  • Page 265 To ensure proper positioning of the rods, refer to the figure at right, taking care to observe fitting dimension "X": - Rivale 800: X = 239 mm Bring the two screws (1) into contact at the base of the steering.
  • Page 266 Suspension and wheels Tighten the two screws (1) at the base of the steering. Effectuate the operation several times until the 18 N•m torque wrench does not turn the screw any more. This operation must be carried for both stems. Grease only the first threads.
  • Page 267 To adjust the front suspension, refer to the values given in the following table. Spring preload Rivale 800 Type of geometry (On road) Spring preload Spring preload 4,5 turns...
  • Page 268 Suspension and wheels Compression damper The adjustment is obtained from the reference posi- tion, which is found by fully turning the screw clockwise and then counterclockwise until you reach the standard position (see table). Rotate clockwise to increase the damping action or counterclockwise to decrease it. - 24 -...
  • Page 269 Suspension and wheels STEERING ASSEMBLY N·m 16 ÷ 18 Into contact 22 ÷ 24 Torque +10° pressure Kg·m ft·lb Operation - 25 -...
  • Page 270 Suspension and wheels STEERING ASSEMBLY OVERHAUL In order to operate on the steering unit, the first han- dlebar unit must be removed by loosening the two screws (1) and sliding them out. Fold the handlebar over the headlight, protecting it with a cloth.
  • Page 271 Suspension and wheels To operate on the steering assembly, it is necessary to remove the fork stems as described in this chapter, in the paragraph “Front fork overhaul”, or lift the front wheel using the specific kickstand. Special tool No. 800095807 and No. 8000B7340 Then remove the components according to the follow- ing order: - front headlight;...
  • Page 272 Suspension and wheels Steering base removal Utilising the special tool, slacken the screw ring of the steering pin. Support the motorcycle sufficiently enough so that the front stand can be removed. Ensure that the brake calipers are securely placed. Special tool No. 800091645 Remove the screw ring (1) previously slackened.
  • Page 273 Suspension and wheels Remove the steering base from the lower part. Assembly steering base Accurately clean all the parts and check the general condition. Before reassembly, grease the internal ring of the bear- ing and the ball bearing ring on the steering pin with Agip Grease 30.
  • Page 274 Suspension and wheels Steering pin tightening 10° Screw down, without tightening, the screw ring of the steering pin. 30° This operation must be done manually. Ensure that the steering base is at the end of stroke, completely steered to the right. Utilising the special tool, tighten the screw ring (1) by rotating it 10°...
  • Page 275 55 ÷ 60 70 ÷ 75 Torque Kg·m pressure ft·lb Operation Description Rivale 800 REAR SUSPENSION Type Progressive, single shock absorber with extension, compression and spring preload adjustment Swingarm Aluminium alloy Wheel travel (mm) During the disassembly and check of the rear suspension assembly, it is advisable to disassemble the fuel tank, as described in chapter C “Bodywork”...
  • Page 276 Suspension and wheels Rear shock absorber disassembly Remove the saddle, the passenger foot peg supports, the number carrier side panels with the headlights and the under-saddle bulkhead, as described in Chapter C “Fairing”. Lift up the rear part of the motorcycle with the specific lifter.
  • Page 277 Suspension and wheels Remove the bottom nut (2) of the damper and slide the screw out, discharging the weight of the shock absorber. Extract the complete shock absorber, discharging the weight of the same. Rear shock absorber test Make sure that the top connection of the damper (ball joint) does not have any axial (A) or radial (B) play.
  • Page 278 Suspension and wheels Check the length of the rear shock absorber spring. Standard spring adjustment (A): - Rivale 800: A = 160 mm Check the functioning of the adjusters. The shock absorber contains high-pressure gas. Do not touch the valve of the shock absorber tank.
  • Page 279 Suspension and wheels Rear shock absorber assembly Accurately clean all parts. Grease the screws with Agip Grease 30 before reassembly. Insert the shock absorber from above and lightly screw in the lower screw of the shock absorber using the rel- ative nut.
  • Page 280 Suspension and wheels SWINGARM REMOVAL AND OVERHAUL Remove the rear damper as described in the previous pages. Rear wheel removal Remove the rubber and the safety spring clip (1) and unscrew the screw ring of the wheel. Attention! The screw ring has a left-handed thread.
  • Page 281 Suspension and wheels Footrest 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). Operate on the two screws (1) of both the right and left foot peg supports and remove them.
  • Page 282 Suspension and wheels Lower chain guard removal Remove the two socket head screws (1) of the lower chain guard. Remove the lower chain guard, taking care to recover the internal bushes. Top chain guard removal Remove the two top chain guard screws (1). Silencer disassembly Remove the clamping screw on the lh side.
  • Page 283 Suspension and wheels Remove the socket head screw on the right side. Remove the silencers unit from the exhausts. - 39 -...
  • Page 284 Suspension and wheels CHAIN REMOVAL Remove the chain utilising the special tool. Special tool No. 800095389. Identify the connecting link. The part of the tool being indicated must operate on the internal part of the crown wheel. The tool has three functions: NOTE •...
  • Page 285 Suspension and wheels REASSEMBLING CHAIN 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. Utilise only new links. Connect both ends of the chain with the connecting link, and press the connecting plate into the connecting pins by hand.
  • Page 286 Suspension and wheels Suspension and wheels 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. Tighten at the specified torque.
  • Page 287 Suspension and wheels Removing the rear brake caliper Loosen the two screws (1) and remove brake caliper (2). Speed sensor cable disassembly Remove the speed sensor cable holding clamp (3). Disconnect the speed sensor cable connector (1). - 43 -...
  • Page 288 Suspension and wheels Swingarm pin removal Before removing the swingarm pin, loosen the suspen- sion rocker pin (1) and the two engine pins (2). (See chapter G “Frame”). Also loosen the pin for the pads. Remove the screw (1) on the left side of the vehicle. Remove the washer and push out the pin (2) manually.
  • Page 289 Suspension and wheels Suspension and wheels 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. Upper chain guide removal Remove the 2 screws (1) and relative plates and the screw (2) on the front.
  • Page 290 Suspension and wheels 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. Lower chain guide removal Remove the 3 screws (1) with their relative spacers.
  • Page 291 Suspension and wheels Utilising the special tool press on both ball bearings and extract them. Operate in the same way for the bearings on the left side. Special tool No. 800092860 RIGHT SIDE Extract the spacer from the right side. Check the condition of both bearing seats and the seat of the spacer.
  • Page 292 Suspension and wheels Complete the assembly by fitting the two bushings relating to the tool Part No. 800092866 on the right side of the swingarm. Special tool No. 800092866 Utilising a press fit the bearings and the roller bearing units (see figure). - 48 -...
  • Page 293 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 Rivale 800 REAR WHEEL Material Aluminium alloy Dimensions 5.50” x 17” REAR TYRE Dimensions 180/55 ZR 17 M/C (73W) Brand and type PIRELLI - Diablo Rosso Corsa...
  • Page 294 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. 8000B9312 Remove the number plate carrier-mudguard unit (as described in chapter C) and the rear wheel by remov- ing the polygonal nut.
  • Page 295 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. With the special spanner mounted on the extension tube, pull forward the eccentric adjuster and slacken the chain.
  • Page 296 Suspension and wheels Remove the rear sprocket unit (3) and the spacer ring (5) underneath. Remove the rubber clamp (1) around the rear brake pipe. Slacken the two screws (6) and remove the brake caliper (7). - 52 -...
  • Page 297 Suspension and wheels Disassembly of the wheel pin Remove the wheel spindle complete with the brake 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 298 Suspension and wheels Wheel hub disassembly Extract the wheel hub from the left side of the fork. 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 bear- ings) or chamferings during rotation, substitute the wheel hub, complete with bearings with a new unit.
  • Page 299 Suspension and wheels Wheel spindle unit check Check the condition of the wheel drive engagement 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 300 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 20÷22 N•m engagement. When assembling, apply force on the crown of the peg not on the point.
  • Page 301 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. Flexible coupling check Extract the 5 spring drives (2) from the gear flange sup- port (3) and assess its condition.
  • Page 302 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 303 Suspension and wheels To assemble the brake caliper-carrying flange, carry out the following operations: Grease the O-rings and insert them into their respec- tive seats on the flange. Assemble the rear spacer ring in contact with the hub, then the brake caliper-carrying flange, the second spacer ring and the Seeger retaining ring (1).
  • Page 304 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 305 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 wheel pin fixing nut by rotating it clockwise as shown in the figure, by using the following tools: •...
  • Page 306 Suspension and wheels Remount the number plate carrier unit as described in chapter C. Pinion disassembly Remove the gear shift fixing (1). Remove the covering on the pinion lid by loosening the three screws (1) and allow the gear shift rod to disen- gage from the work area (2).
  • Page 307 Suspension and wheels Remove the 3 clamping screws (2) and remove the pinion cover (1). 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. - 63 -...
  • Page 308 Suspension and wheels Unscrew the pinion wheel retaining nut. Now cut and remove the chain as described on page 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.
  • Page 309 Suspension and wheels Hammer the new washer down onto the two opposite faces of the hexagon. Remove the chain as described on pages 41-42. Reassemble the pinion wheel cover after having cleaned the support base. 10 N•m Proceed with the tightening, screwing down respec- tively on the three screws M6 (1).
  • Page 310 Two persons must carry out this opera- NOTE tion. Check that dimension X is equal to: Rivale 800: = 312 mm Press down the saddle to compress the rear shock absorber, then allow the vehicle to spring back to its rest position.
  • Page 311 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 Δ value of static sag. - Rivale 800: Turn anticlockwise Turn clockwise Special tool: 75 mm hook wrench No. 80000B7038 Δ...
  • Page 312 Suspension and wheels WHEEL BALANCE CHECK If the tyres are substituted, it is necessary to effectuate 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 313 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 314 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 lightest point of balancing and must be situated close to the tyre valve when the tyre is mounted onto the wheel rim.
  • Page 315 Frame SECTION Revision 0 - 1 -...
  • Page 316 Frame SUMMARY PRELIMINARY OPERATIONS........................PAGE 3 BATTERY CABLES...........................PAGE 3 FOOT PEG REMOVAL..........................PAGE 5 EXHAUST SILENCER DISASSEMBLY....................PAGE 6 EXHAUST MANIFOLDS REMOVAL......................PAGE 7 FRAME REMOVAL PRELIMINARY OPERATIONS .................PAGE 9 CONTROL UNIT REMOVAL ........................PAGE 10 BATTERY BOX REMOVAL ........................PAGE 12 GLOVE COMPARTMENT REMOVAL....................PAGE 13 REMOVAL OF IGNITION SWITCH ......................PAGE 14 EXPANSION TANK REMOVAL......................PAGE 16 DISCONNECTING THE HORN ......................PAGE 19...
  • Page 317 Frame PRELIMINARY OPERATIONS To perform the interventions on the frame, the follow- ing must be removed previously in sequence: - Saddle - Saddle side panels - Fuel tank side panels - Side number holder - Fuel tank - Airbox BATTERY CABLES It is a good rule to disconnect the battery cables before removing components from the motorcycle.
  • Page 318 Frame Disconnect the positive pole of the battery. Remove the battery from its compartment. - 4 -...
  • Page 319 Frame FOOT PEG REMOVAL Act on the 2 screws (1) of both foot peg mountings and remove them. On the right foot peg, also remove the silencer clamping screw (2). - 5 -...
  • Page 320 Frame EXHAUST SILENCER DISASSEMBLY Remove the clamping screw (1) on the left side. Remove the socket head screw (2) on the right side. Slide the silencer unit out from the exhausts towards the rear part of the motorcycle. - 6 -...
  • Page 321 Frame EXHAUST MANIFOLDS REMOVAL This operation is not necessary for disas- NOTE sembly of the engine or frame. Proceed as described below for exhaust manifold replacement. Disassemble the water radiator and oil radiator before- hand, as described in chapter L "Cooling system". Slide off the Lambda probe connector (1) and lift.
  • Page 322 Frame 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 323 Frame FRAME REMOVAL PRELIMINARY OPERATIONS Support the motorcycle with the aid of the following stands: - Code 8000B9312: Rear stand - Code 800095807: Front stand - Code 8000B7340: Front stand pin - Code 8000B6789: Engine support Remove the following components in order: - Front mudguard;...
  • Page 324 Frame CONTROL UNIT REMOVAL This operation is not necessary to disas- NOTE semble the frame. Slide the control unit complete with rubber support from the battery holder seat. Disconnect the two connections acting on the safety flaps with a flat screwdriver. Turn the bayonet connector anti-clockwise to remove wiring from the control unit.
  • Page 325 Frame Remove the control unit from the motorcycle. If the battery has not yet been removed, do so as described in the “Maintenance” chapter. - 11 -...
  • Page 326 Frame BATTERY BOX REMOVAL Remove the two lateral screws (1). Remove the central screw (2). Remove the four relays (3). - 12 -...
  • Page 327 Frame Remove the battery box. GLOVE COMPARTMENT REMOVAL Remove the glove compartment fixing screw (1). Slide the glove compartment (2) from the upper part. - 13 -...
  • Page 328 Frame REMOVAL OF IGNITION SWITCH Remove the two M6 screws fixed with Loctite (1). Remove the three rubber band fasteners (2). Disconnect the connector (3). - 14 -...
  • Page 329 Frame Cut the safety band fastener on the temperature sen- sor (4). Remove the complete ignition switch (5). - 15 -...
  • Page 330 Frame EXPANSION TANK REMOVAL Remove the three fixing screws (1) of the expansion tank. Push the expansion tank out of the frame and remove it from the vehicle. Remove the four rubber band fasteners of the vent pipes (2). - 16 -...
  • Page 331 Frame Pull the vent pipe from the upper part of the frame. Remove the click band fastener (3) on the pipe from the radiator cap to the radiator. Remove the pipe from the radiator. - 17 -...
  • Page 332 Frame Slide the pipe out from inside the frame. Slide the pipe and the expansion vessel out from the upper part of the motorcycle. Empty the liquid from the expansion vessel completely into a basin. - 18 -...
  • Page 333 Frame DISCONNECTING THE HORN Disconnect the 2 connectors (1) from the horn. THROTTLE BODY REMOVAL Protect the frame by applying adhesive tape as shown in figure. Remove the 2 cable-retaining clamps (1). - 19 -...
  • Page 334 Frame Disconnect the pressure sensor (2). Remove the safety band fastener (3). Disconnect the 3 injector connectors (4). - 20 -...
  • Page 335 Frame Disconnect the 6 clamping screws (5) of the throttle body to the intake flange. Remove the throttle body first lifting it from the left as shown in figure. Disconnect the DBW control connection (6). - 21 -...
  • Page 336 Frame Protect the air intake lines using adhesive tape in order to avoid dirt from getting into the cylinders. For reassembly proceed the opposite order as disas- sembly, applying the following procedure to tighten the throttle body screws: - Tighten the 6 fixing screws of the throttle body at a tightening torque of 10 Nm, respecting the tightening sequence shown in the figure.
  • Page 337 Frame REMOVING THE SEAT LOCK Remove the two M5 nuts (1) fixing the lock support to the frame. To remove the nut at the bottom, the starter cable nut with screw must also be disassembled (2) and the nut must be removed manually. Slide the lock complete with support from inside the motorcycle.
  • Page 338 Frame REMOVING THE MAIN CABLING To remove the main cabling it is necessary to discon- nect all of the connections and remove all the rubber clamps. Disconnect the three plug-top connectors. Disengage the yellow tab (1). Lift the black tab (2). At the same time as lifting the black flap, release the connector (3).
  • Page 339 Frame Remove the engine rpm pick-up. Remove the current generator connection. Remove the gear position sensor. - 25 -...
  • Page 340 Frame Remove the engine coolant temperature sensor. Remove the rear wheel speed sensor (operation not essential). Position all of the wiring on the small frame. - 26 -...
  • Page 341 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. - 27 -...
  • Page 342 Frame FRAME REMOVAL FROM THE ENGINE Operating as shown in the figure, unscrew and remove the front screw (1) fixing the engine to the frame from the left side, recovering the nut and spacer (2) from the right side. Unscrew and remove the upper screws fixing the frame to the plate from both sides.
  • Page 343 Frame Take the engine clamping pin out from the left side of the frame. Supporting the front part of the frame, shift it towards the front. Remove the frame from the engine by lifting. - 29 -...
  • Page 344 Frame FRAME CHECKS AND INSPECTION Clean thoroughly and check the housings of the steer- ing bearings. 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.
  • Page 345 This procedure is recommended by MV Agusta in order to guarantee the motorcycle’s safety for the final customer and third parties in general. Failure to comply...
  • Page 346 Frame FRAME MEASUREMENTS CONTROL DIAGRAM - 32 -...
  • Page 347 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. - 33 -...
  • Page 348 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 349 Frame Once the frame has been re-installed, re-install the electrical cabling. See Chapt. E - Electrical System regarding the posi- tioning and passage of cables, clamps and wiring. - 35 -...
  • Page 350 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 351 Frame - 37 -...
  • Page 352 Frame REAR FRAME DISASSEMBLY After having carried out the removal of all the neces- sary components described in the previous paragraph, perform the following operations. Remove all rubber band fasteners holding the wiring until the frame appears as in the photo. Disconnect the voltage regulator connector.
  • Page 353 Frame REMOVAL OF THE STARTER CONTACTOR AND FUSE BOX Remove the fixing screw (1) of the contactor protection (2). Remove the contactor protection (2) towards the rear part. Slide the double control unit out on the right side (3) (intermittence and tail light diagnosis). - 39 -...
  • Page 354 Frame Rewind the saddle lock cable (1) onto the rear frame. Unscrew and remove on both sides the two lower screws fixing the rear sub-frame to the union plates taking care to recuperate the nuts. Unscrew and remove the two upper fixing screws tak- ing care, in this case also, to support the sub-frame and recuperate the nuts.
  • Page 355 Frame REAR FRAME UNIT ASSEMBLY Carry out the operation of reassembling the rear sub- frame on the motorcycle in the reverse order of removal, taking care to tighten the fixing screws to the prescribed torque pressure. Rear sub-frame fixing screw torque pres- sure: 24÷28 N•m 24÷28 N•m - 41 -...
  • Page 356 Frame ENGINE REMOVAL Cut the chain as described in chapter F "Suspension and Wheels." Remove the brake oil tank in the inside of the right plate. Operating as shown in the figure, remove the plate fix- ing screw from the left side. Remove the lower screw fixing the plates to the engine from the left side.
  • Page 357 Frame Loosen the swing arm pin to widen the plates respect to the engine. Operating as shown in the figure, loosen the lower screw fixing the plates to the rocker arm to widen the plates respect the engine. Using a rubber mallet, slightly widen the plates as shown in the figure to be able to push the engine towards the front part.
  • Page 358 Frame Using a flat screwdriver, move aside the centring bush- es (1) between the plates and engine (one on each side) and remove them by hand. Insert a support to bear the plates. Disconnect the gear rod (2) removing the screw of the gearshift transmission (3).
  • Page 359 Frame Disconnect the rear wheel speed sensor connector (1). Disconnect the hydrostop sensor connector (2). Disconnect the number plate carrier group (3) connec- tor. - 45 -...
  • Page 360 Frame Slip the engine forwards. 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 the engine removal.
  • Page 361 Brakes SECTION Revision 0 - 1 -...
  • Page 362 Brakes SUMMARY FRONT BRAKE SYSTEM ............PAGE 3 REMOVING FRONT MUDGUARD .
  • Page 363: Front Brake System

    16 ÷ 18 42 ÷ 46 23 ÷ 26 23 ÷ 25 Torque Kg·m pressure ft·lb Operation Description RIVALE 800 FRONT BRAKE Type Dual floating disc with steel braking band Ø discs (mm) Disc flanges Steel Calipers (Ø pistons mm) Radial-type, with 4 pistons Ø...
  • Page 364 Brakes REMOVING FRONT MUDGUARD To facilitate replacement of the front brake pads, remove the front mudguard as described in Chapter C “Superstructures”. FRONT BRAKE PADS SUBSTITUTION Remove the safety catch (1). Loosen the pads pin (2). - 4 -...
  • Page 365 Brakes Remove the pads pin (2). Slide the safety plate out (3). Remove the two pads (4). - 5 -...
  • Page 366 Brakes 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. Brake Disc Brake Wear limit 1 mm For setting up front brake pads, carry out the opera- tions described above in reverse order.
  • Page 367 Brakes Remove the protection cap of the bleed valve of the front right caliper. Apply a rubber tube to the bleed valve (the valve is placed on the summit of the brake caliper). Put the other end of the rubber tube in a suitable con- tainer.
  • Page 368 Brakes Fill the system by pulling the front brake lever 3-4 times (see figure). Repeat the above drain operations until the fluid reach- es the minimum level in the reservoir. Top up with fresh fluid and carry on with the operation until fluid of a dif- ferent colour (fresh) flows out.
  • Page 369 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 370 Brakes Accurately clean the three elements of the brake fluid chamber cap with alcohol and dry with compressed air. Use a clean cloth to clean also after having positioned the membrane. Position and screw on the top brake fluid tank cap and tighten the two lateral fixing screws.
  • Page 371 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 operations. Unscrew the fitting with a 12mm key, being careful to avoid spilling any brake fluid.
  • Page 372 Brakes Remove the brake caliper. The removal operation is identical for both NOTE calipers. To fit the front brake calipers, follow these steps: 23÷26 N•m 42÷46 N•m - Insert the caliper fixing screws and turn them it until they make contact. Only grease the first threads of the brake caliper fixing screw.
  • Page 373 Brakes Remove the three fixing screws (1) of the cover. Remove the hand guard front fixing (2). Remove the two hand guard lateral fixing screws (3). - 13 -...
  • Page 374 Brakes Leave the hand guard hanging as indicated (4). Remove the two hand guard plate fixing screws (5). Remove the two clips of the front brake stop (6). - 14 -...
  • Page 375 Brakes Remove the hand guard fixing plate (7). Remove the pump bar clamp fixing screws (8). - 15 -...
  • Page 376 Brakes Remove the union (11) 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 377 Brakes FRONT BRAKE LEVER REMOVAL Unscrew the blocking nut. Unscrew the pin and remove it; then remove the brake lever. When reassembling take care to insert the lever into its seat. Grease the pin: Recommended grease: Agip Grease 30 Insert the pin into the seat and screw it in until the beat is reached, then tighten the nut by using a screwdriver.
  • Page 378 Brakes FRONT BRAKE DISCS Check the thickness of the front discs utilising a micrometer gauge and measure three points at least with 120° between them as shown in the figure. Use a micrometer gauge for this check. - Minimum allowable thickness: 4.5 mm This operation just be carried out on both front discs.
  • Page 379 Brakes Front disc assembly Thoroughly clean the contact surfaces of the discs and the wheel. Accurately grease all relative surfaces of the disc before reassembling. The following operation is to be carried out on all models. If newly supplied screws are being used they already have threadlocker on them.
  • Page 380: Rear Brake System

    16 ÷ 18 8 ÷ 10 Torque Kg·m pressure ft·lb Operation Description RIVALE 800 REAR BRAKE Type Single steel disc Ø discs (mm) Caliper (Ø pistons mm) With 2 pistons Ø 34 Rear disc thickness (mm) Min. pads thickness (mm)
  • Page 381 Brakes REAR BRAKE PADS SUBSTITUTION Remove the safety retainer and unscrew the rear ring 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 382 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 caliper from the support by removing the 2 fixing screws. Remove the brake pads. Carry out the check every 6000 kilometres.
  • Page 383 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 perform this operation, the tank must be removed (1) complete with support bracket (2) from the frame plate.
  • Page 384 Brakes Be careful to not spill the fluid from the reservoir during these operations. Brake fluid is extremely corrosive. Avoid contract with the eyes, skin and nose. Wash abundantly with water if contact is accidentally made and consult a doctor. During the successive operations, avoid spilling the fluid onto painted surfaces.
  • Page 385 Brakes Before closing the fluid reservoir, check the condition of the components. 8÷10 N•m Carry out bleeding also on the front brakes (see the paragraph in this chapter). During tank re-assembly apply the required torque pressure to the screw (1) that clamps the supporting bracket to the plate of the frame.
  • Page 386 Brakes Remove the 2 screws indicated in the figure and take off the caliper. Remove the fitting to disconnect the caliper. For caliper reassembly, tighten the two screws to the prescribed torque pressure. Recommended threadlocking product: Loctite 243 Torque pressure: 18 N·m 18 N•m Assemble the union tightening to the prescribed torque.
  • Page 387 Brakes Rear brake pump removal Loosen the two fixing screws (1) of the front right foot peg support (2). Loosen the exhaust foot peg support fixing screw (3). Loosen the two M6 screws (4) that hold the foot peg support fixed to the pump. - 27 -...
  • Page 388 Brakes Disassemble the clips complete with pin (5). Unscrew connection (6) as shown in the figure so as to disengage the pump from the brake line. Loosen the retaining clamp (7) sliding it off the work zone upward and slip off the brake fluid hose (8). - 28 -...
  • Page 389 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 reverse order of removal. Substitute the gaskets of the pump/caliper NOTE hoses. Tighten the fixings to the prescribed torque pressure. Torque pressure pump union: 16÷18 N·m Conclude the operations by filling the system with brake fluid and successively bleeding the system (see...
  • Page 390 Brakes REAR BRAKE DISC REMOVAL Before proceeding with the removal of the rear brake disc, it is necessary to carry out certain operations described below: - Remove the rear wheel. - Remove the rear wheel pin from the motorcycle (See chapter F).
  • Page 391 Brakes Check the thickness of the rear brake disc by utilising a micrometer gauge and measuring at least at three points with 120° between them. The minimum thickness of the disc must not be less than 4.7 mm. Utilise a micrometer gauge for this check. Before fitting the rear brake disc, check the condition of the four pins.
  • Page 392 Brakes - 32 -...
  • Page 393 Cooling system SECTION Revision 0 - 1 -...
  • Page 394: Cooling System

    Cooling system SUMMARY COMPLETE COOLING SYSTEM ASSEMBLY ..........PAGE 3 COOLING SYSTEM LEAKAGE CHECK .
  • Page 395 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 396 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 fuel tank, the airbox, the seat and the underseat panels (see chap. C “Upper structures”). Remove the water radiator cap and connect the tester (of the type shown in the diagram) to the filler hole.
  • Page 397 Cooling system WATER RADIATOR CAP CHECK Check the release pressure of the radiator cap by util- ising the appropriate tester as follows: Apply the cap to the tester as indicated and slowly cre- ate a pressure by activating the tester. Make sure that the increase in pressure is interrupted at 110±15 kPa (1.1±0.15 kg/cm ) and check that with...
  • Page 398 Cooling system • Tilting the motorcycle ∼30° on its right side, let the liq- uid flow out paying attention to where it pours; • Using a funnel and tilting the motorcycle further, have all the coolant empty into the collection container; •...
  • Page 399 Cooling system REMOVING EXPANSION TANK After having emptied the cooling system, as described in the previous paragraph, in order to remove the expansion tank you must first remove the seat, the tank panels, the fuel tank, the right and left intake ducts, the air filter, the airbox and the radiator panels (right and left) as described in Chapter C "Upper struc- tures".
  • Page 400 Cooling system Operating on the right side of the vehicle, remove the CLIC R 66-100 clamp connecting the water radiator vent hose to the expansion tank using the special pli- ers CLIC R 205. Special CLIC R 205 pliers tool. When performing reassembly, check the NOTE conditions of the clamp and replace it if it...
  • Page 401 Cooling system WATER RADIATOR DISASSEMBLY After having emptied the cooling system, proceed as follows to remove the radiator: 1) Remove the right and left radiator side panels, removing the three M4 screws (1) and the three M5 screws (2) with collar. 2) Disconnect the water temperature sensor.
  • Page 402 Cooling system 3) Disconnect the radiator fan connector. 4) Operating on the left side of the vehicle, remove the sleeve clamp of the hose from the radiator to the pump using the special pliers CLIC R 205. Special CLIC R 205 pliers tool. 5) Slip the hose from the sleeve leaving a collection container underneath the vehicle to recover any liq- uid left in the hose.
  • Page 403 Cooling system 6) Operating on the right side of the vehicle, disconnect the sleeve clamp of the hose from the radiator to the head using the special pliers CLIC R 205 and pull the hose off. Special CLIC R 205 pliers tool. Successively, disconnect the vent pipe band fasten- er (radiator side).
  • Page 404 Cooling system One screw is placed on the right side of the vehicle. 8) Release the water radiator from the frame by remov- ing the two special screws positioned on the left and right side of the vehicle. 9) At this point, the water radiator is disengaged from the frame.
  • Page 405 Cooling system 10) Release the clutch hose from the clip on the water radiator. 11) Disengage the water radiator from the oil radiator, releasing it from the seat of the pin located on the oil radiator, pushing the water radiator from right to left.
  • Page 406 Cooling system 13) The vehicle remains in the conditions shown in the figure to the side with the oil radiator suspended on the engine pipes. - 14 -...
  • Page 407 Cooling system DISASSEMBLY OF THE WATER RADIATOR PARTS Disassembly of the electric fan Remove the 2 screws that clamp the conveyor to the radiator. Lift the conveyor and slide it from the retaining pins. Turn the conveyor by 180° and unscrew the 4 screws that clamp the fan to the conveyor.
  • Page 408 Cooling system Remove the fan. Disassembly of the radiator clamping elements Slide off the 2 threaded circlips. - 16 -...
  • Page 409 Cooling system Pull the spacer from the lower support bracket. Remove the silent block from the lower fixing bracket. Remove the 2 silent blocks from the fan conveyor bracket. - 17 -...
  • Page 410 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 411 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 412 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 413 Cooling system Position the complete electric fan on the radiator. Position the electric fan wiring as indicated in the fig- ure, verifying the correct positioning of the anchoring clamps. 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.
  • Page 414 Cooling system THERMOSTAT REMOVAL Remove the 2 fixing screws of the thermostat cover. Remove the cover of the thermostat (1). Remove the thermostat (2). - 22 -...
  • Page 415 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 416 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 417 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. - 25 -...
  • Page 418 Cooling system OIL RADIATOR DISASSEMBLY To disassemble the oil radiator together with the hoses, the water radiator must be disassembled as well. To avoid oil leakage during disassembly, lift the motor- cycle with specific tools. Specific tool front stand: 800095807 Specific tool pin: 8000B7340 Specific tool rear stand : 8000B9312 Position an oil collecting basin under the pipes.
  • Page 419 Cooling system Successively, disconnect the vent pipe band fastener (radiator side). Remove the three fixing screws TORX TX 27 of the hose support plate and pull it downwards. Pull off the connection pipes from the engine block one at a time and let leftover oil empty into the tray. - 27 -...
  • Page 420 Cooling system Remove the oil radiator. Check the integrity of the component and if needed straighten the bent fins using a screwdriver or tweezer. - 28 -...
  • Page 421 Cooling system OIL RADIATOR COMPONENT DISASSEMBLY Removing the connecting pipes Take the retaining screw off of the plate. Slide the pipe out, making sure not to ruin the O-Rings. Do the same with the other one. Removal of spacers and silent blocks Pull the two spacers from the upper support brackets anchoring the water radiator.
  • Page 422 Cooling system Slip the three silent blocks from the three upper support brackets. 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.
  • Page 423 Cooling system Insert the fixing screws of the supply and return radia- tor hose retaining plate but do not tighten them. Insert the supply and return pipes in their housing on the motor block. Position the hose support plate and insert the three fix- ing screws without tightening them.
  • Page 424 Cooling system Put the oil support plate back in place inserting the two screws without tightening them. Before tightening the entire unit, wait for the oil radia- tor to be mounted on the water radiator in order to pro- vide the right orientation at the oil tubes. If the hoses are not deformed in this position, tighten the screws in the following order: - tighten the three screws fixing the water radiator to...
  • Page 425 Cooling system One screw is placed on the right side of the vehicle; - tighten the three fixing screws of the hose support plate; - tighten the two screws fixing the supply and return pipe retaining plate to the oil radiator; - 33 -...
  • Page 426 Cooling system - tighten the two screws fixing the radiator support plate to the engine; When you have finished tightening the unit, make sure the hoses respect the orientation shown in the figure. ATTENTION: The oil hoses must be the right distance from the drain pipes to keep oil from overheating.
  • Page 427 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 428 Cooling system Close the loading hole with the screw-on cap and tight- en it at the prescribed tightening torque. Torque pressure: 7 ÷ 8 N·m 7 ÷ 8 N•m Start the engine, keeping it running long enough to heat the fluid until the cooling fan begin operating, then turn the engine off.
  • Page 429 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 - 37 -...
  • Page 430 Cooling system SYSTEM FUNCTIONING CHECK Assemble the following components in order: • Airbox. • Fuel tank. • Rear side panels (n°2 items for each side). • Radiator side panels. • Air intake ducts. • Air outlet side panels. • Saddle. For the assembly operations, assemble in reverse order of removal.
  • Page 431 Special tools SECTION Revision 0 - 1 -...
  • Page 432 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 433: Special Tools

    Special tools Code Q.ty Note Rivale 800 Descrizione Description 800095830 • Cavalletto Front stand anteriore 800091645 • Chiave ghiera Steering bearing cuscinetti di sterzo pin wrench 8000B6920 • Attrezzo montaggio Rear suspension cuscinetti tiranti tie rod bearings sospensione post mounting tool 800092860 •...
  • Page 434 Special tools - 4 -...
  • Page 435 Special tools Code Q.ty Note Rivale 800 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 • Perno taglio e Cutting and...
  • Page 436 Special tools - 6 -...
  • Page 437 Special tools Code Q.ty Note Rivale 800 Descrizione Description 8000B7177 • Attrezzo montaggio Gear change cambio mounting tool 800079015 • Attrezzo bloccaggio Clutch blocking frizione tool 800094796 • Piastra montaggio/ Valves installation/ smontaggio valvole removal plate 8000B7207 • Piastra montaggio...
  • Page 438 Special tools - 8 -...
  • Page 439 Tightening torques SECTION Revision 0 - 1 -...
  • Page 440 Tightening torques - 2 -...
  • Page 441 Tightening torques - 3 -...
  • Page 442 Tightening torques - 4 -...
  • Page 443 Diagnostic SECTION Revision 0 - 1 -...
  • Page 444: Electrical Components

    Diagnostic ELECTRICAL COMPONENTS BATTERY CHARGING SYSTEM Battery warning light on Check the condition of the fuse on the remote switch Replace 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...
  • Page 445 Diagnostic Low beam does not work Bulb burnt out Replace Bulb connections faulty Deoxidize/Repair 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 The stop light does not work or always stays on Stop light bulb burnt out Replace Bulb connections faulty...
  • Page 446 Diagnostic Battery warning light does not work Instrument panel broken Replace Instrument panel connection faulty Deoxidize/Repair ECU failure Replace Faulty ECU connection Deoxidize/Repair ABS system warning light does not work Instrument panel broken Replace Instrument panel connection faulty Deoxidize/Repair ECU failure Replace Faulty ECU connection Deoxidize/Repair...
  • Page 447 Diagnostic ABS SYSTEM (Perform testing using TEXA diagnostic software) ABS system warning light on Faulty front/rear speed sensor connection Deoxidize/Repair Front/rear speed sensor damaged Replace Broken or damaged phonic wheel Repair/Replace Gap between sensor and phonic wheel not as specified Replace Fuse 25A connection faulty Deoxidize/Repair...
  • Page 448 Diagnostic COIL N Faulty specified reel connection Deoxidize/Repair Specified coil broken Replace ECU failure Replace Faulty ECU connection Deoxidize/Repair Problem with the electrical system Repair/Replace FAN RELAY Faulty fan relay connection Deoxidize/Repair Fan relay failure Replace ECU failure Replace Faulty ECU connection Deoxidize/Repair Problem with the electrical system Repair/Replace...
  • Page 449 Diagnostic FRAME STEERING Steering stiff Steering bearings damaged Replace 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 450 Diagnostic BRAKES Brake lever and pedal soft (“spongy”) Air bubbles in hydraulic circuit Bleed Leaks in hydraulic circuit Repair Caliper seals damaged Replace Pump seals damaged Replace Caliper pistons do not slide freely Check Brake fluid level low Top up Brake discs distorted Replace Brake lever or pedal stiff...
  • Page 451 Analytical index SECTION Revision 0 - 1 -...
  • Page 452 Analytical index ANALYTICAL INDEX - RIVALE 800 WORKSHOP Tube fastening bands ....B-51 MANUAL Tubes / Fuel fittings .....B-26 Section A - General Description Tyres .
  • Page 453 – Disconnecting the horn ....G-19 Rivale 800 ......E-47 –...
  • Page 454 Frame .......O-7 Section P - Analytical index Analytical index - Rivale 800 workshop manual .P-2 - 4 -...