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Table Of Contents - MV Agusta Rivale 800 Workshop Manual

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User manual (93 pages)

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Table of Contents

General Description7

Table Of Contents8

How To Consult This Manual9

Order Of The Subjects9

Display Of The Operations9

Glossary And Symbols10

Right Hand And Left Hand Standard11

Carbon Monoxide12

Thread-Locking Fluid13

Nitrogen - Rear Shock Absorber13

Operative Technical Specifications15

Motorcycle Identification15

Technical Information19

Technical Data19

Periodical Maintenance Schedule22

Programmed Maintenance Schedule22

Table Of Lubricants And Fluids24

Engine Oil And Oil Filter24

Maintenance And Tuning Operations24

Engine Coolant27

Engine Coolant Substitution29

Electric Cooling Fan31

Valve Mechanism Adjustment31

Timing Chain, Mobile Timing Chain Guide And Timing Chain Tensioner36

Spark Plug Gap37

Electrode Condition37

Removing The Fuel Pump Unit38

Check And Replace The Gasket39

Changing The Thermistor (Reserve Probe) Complete With Cabling39

Replacement The Fuel Filter40

Fuel Pump Assembly41

Installing The Fuel Pump Unit42

Check, Disassembly And Reassembly Fuel Pipe Fittings42

Replacing Fuel Pipe In Tank43

Replacing Fuel Pipe From Throttle Body44

Checking Engine During Idle45

Checking The Level Of The Rear Brake Fluid49

Substitution And Bleeding Of The Brake Fluid51

Front Brake Lever Adjustment52

Adjusting The Clutch Play52

Brake / Clutch / Gearchange Commands Check52

Adjusting The Gear Lever54

Accelerator Control55

Ignition/Steering Block Switch56

"OFF" Position56

"ON" Position56

"LOCK" Position57

Fuel Cap Lock57

Personal Compartment Lock58

Transmission Chain59

Chain Lubrication61

Front Wheel Bearings62

Rear Wheel Hub63

Swingarm Bearings63

Rear Shock Absorber64

Electrical System67

Mounting Battery Terminals68

Instruments And Warning Lights70

Multifunction Display71

Selecting And Setting The Display Functions72

Selecting The Display Functions72

"SPEED LIMITER" Mode73

"CHRONO" Mode74

"QUICK SHIFT" Mode74

Lap Time Recording79

How To Delete Data82

Selecting The Abs Functions85

Clock Settings87

How To Select The Mapping Of The Control Unit88

Setting of "Custom" Mapping88

Warning / Malfunction Alerts96

"SERVICE" Mode98

"UNIT CHANGE" Mode98

Changing The Unit Of Measurement100

Replacing The Headlight Bulb101

Front Headlamp107

Headlight Adjustment107

Superstructures109

Removing Front Mudguard112

Front Headlight Cover Disassembly112

Headlight Support Disassembly114

Dashboard Disassembly115

Removing Handlebar116

Disassembly Of Number Carrier Side Panels And Seat Rail Side Panels121

Removing Fuel Tank124

Removal Of Fuel Tank Cap126

Radiator Side Panels128

Intake Air System - Airbox131

Removing Airbox132

Airbox Removal133

Lower Bulkhead And Tail Light137

Tail Tidy Disassembly138

Foot Peg Support Disassembly139

Disassembly Of The Frame Lower Bulkhead139

Disassembly Of The Glove Compartment Bulkhead140

Removing Number Plate Support140

Disassembly Of The Complete Mudguard Number Plate Carrier Unit144

Tail Light Disassembly150

Disassembly Of Exhaust Guards150

Air Intake Injection System153

Injection System Technical Characteristics155

Injection Time (Injection Volume)155

Injection Time Compensation (Volume)156

Injection Arrest Control156

Fuel Feed System157

Fuel Pressure Regulator158

Fuel Injector158

Fuel Pump Control System159

Atmospheric Air Temperature Sensor160

Intake Air Pressure Sensor160

Ecu (Electronic Control Unit)160

Intake Air Temperature Sensor161

Throttle Body Position Sensors162

Injector Check163

Fuel Pump Check163

Ignition Coils165

Ignition And Injection System Diagnostics166

Diagnostics System166

Eldor Power Unit Fault Codes (With Texa Diagnostic Software)167

Air Intake System Technical Characteristics176

Positions Of Engine-Control System Parts177

Injection System Electrical Diagram178

Engine Control Unit Pinout, Mv Agusta Rivale 800179

Semiconductor Parts184

Electrical Diagram185

Wiring Colour Code186

Charging The Battery190

Removal Of The Battery191

Charging System192

Warning Function192

Battery Efficiency Check194

Battery Current Loss Check194

Battery Current Loss: Less Than 1Ma194

Charge Feed Check194

Starter System195

Checking The Generator199

Starter Motor Removal200

Starter Motor Check201

Starter Motor Assembly201

Starter Relay Check201

Gearchange Position Switch203

Side Stand Switch203

Fuses Rivale 800204

Fuses Rivale 800 Abs204

Engine Pick-Up207

E.a.s. (Electronically-Assisted Gear Shift)207

Timing Wheel Gap208

Run Off Safety Switch208

Instrumentation209

Oil Pressure Sensor210

Fuel Level Warning Light Check Switch210

Water Sensor211

Turn Indicators212

R.p.m. Sensor212

Speed Sensor213

Rivale 800 Abs213

Dipping Beam213

High Beam Headlight214

Licence Plate Light215

Rear Tail Lights And Brake Lights216

Front Turn Indicators Indicator And Side Light217

Rear Turn Indicator Lights218

Cooling Fan System219

Ecu Disassembly220

Engine Control Unit Replacement/Programming220

Replacement Of The Asb Unit221

Engine Control Unit Pinout221

Abs Unit Activation224

Positioning Of Electrical System Wire Clamps Rivale 800227

Positioning Of Electrical System Wire Clamps Rivale 800 Abs240

Suspension And Wheels245

Front Wheel Removal248

Front Wheel Bearing Check250

Front Wheel Bearing Replacement250

Reassembly – Front Wheel Bearings251

Wheel Spindle Check253

Wheel Assembly253

Front Fork Overhaul255

Stem Removal255

Fork Tube Exploding255

Fork Assembly Check260

Assembly Oil Seal And Anti-Dust Seal260

Adjusting The Front Suspension267

Spring Preload267

Rebound Damper267

Compression Damper268

Steering Assembly269

Steering Assembly Overhaul270

Steering Head Removal271

Steering Base Removal272

Assembly Steering Base273

Steering Pin Tightening274

Steering Head Assembly274

Rear Suspension And Swingarm275

Rear Shock Absorber Disassembly276

Rear Shock Absorber Test277

Adjusting The Rear Suspension278

Rear Shock Absorber Assembly279

Swingarm Removal And Overhaul280

Rear Wheel Removal280

Pinion Cover Removal280

Footrest Removal281

Lower Chain Guard Removal282

Top Chain Guard Removal282

Silencer Disassembly282

Chain Removal284

Reassembling Chain285

Riveting Of Pin286

Removing The Rear Brake Caliper287

Speed Sensor Cable Disassembly287

Swingarm Pin Removal288

Upper Chain Guide Removal289

Lower Chain Guide Removal290

Bearings Overhaul290

Disassembly Of The Wheel Pin297

Brake Caliper Support Flange Removal297

Wheel Hub Disassembly298

Caliper Holder Pin298

Wheel Spindle Unit Check299

Crown Wheel Assembly Check300

Flexible Coupling Check301

Reassembly Wheel Hub302

Reassembly Rear Wheel Pin303

Rear Wheel Assembly305

Pinion Disassembly306

Motorcycle Set-Up Adjustment310

Wheel Balance Check312

Front Wheel Balancing312

Rear Wheel Balancing312

Preliminary Operations317

Battery Cables317

Foot Peg Removal319

Exhaust Silencer Disassembly320

Exhaust Manifolds Removal321

Frame Removal Preliminary Operations323

Control Unit Removal324

Battery Box Removal326

Glove Compartment Removal327

Removal Of Ignition Switch328

Expansion Tank Removal330

Disconnecting The Horn333

Throttle Body Removal333

Removing The Seat Lock337

Removing The Main Cabling338

Removing Clutch Control Transmission341

Frame Removal From The Engine342

Frame Checks And Inspection344

Frame Measurements Control Diagram346

Steering Bearings Housing Check347

Frame Assembly Pn The Vehicle348

Rear Frame Disassembly352

Removal Of The Starter Contactor And Fuse Box353

Rear Frame Unit Assembly355

Engine Removal356

Re-Assembly Of The Vehicle360

Front Brake System363

Front Brake Pads Substitution364

Substitution And Bleeding Of The Front Brake Fluid366

Front Brake Calipers Substitution371

Front Brake Pump Removal372

Front Brake Lever Removal377

Front Brake Disc Removal378

Front Disc Assembly379

Rear Brake System380

Rear Brake Pads Substitution381

Substitution And Bleeding Of The Rear Brake Fluid383

Rear Brake Caliper Substitution385

Rear Brake Pump Removal387

Rear Brake Disc389

Rear Brake Disc Removal390

Cooling System393

Complete Cooling System Assembly395

Cooling System Leakage Check396

Checking Expansion Tank Cap396

Water Radiator Cap Check397

Draining The Coolant397

Removing Expansion Tank399

Water Radiator Disassembly401

Disassembly Of The Water Radiator Parts407

Disassembly Of The Electric Fan407

Disassembly Of The Radiator Clamping Elements408

Disassembly Of The Liquid Temperature Sensor410

Assembly Of The Liquid Temperature Sensor412

Water Radiator Group Assembly412

Cooling Fan Motor Check412

Thermostat Removal414

Thermostat Assembly416

Water Radiator Vehicle Unit Assembly417

Oil Radiator Disassembly418

Oil Radiator Component Disassembly421

Removing The Connecting Pipes421

Removal Of Spacers And Silent Blocks421

Oil Radiator Assembly422

Filling The Cooling System427

Motor Oil System Filling429

System Functioning Check430

Motor Oil System430

Special Tools431

Maintenance Tools432

Tightening Torques439

Electrical Components444

Analytical Index451

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