MV Agusta Brutale 990 R Service Manual
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MV Agusta Brutale 990 R Service Manual

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  • Page 2 ©2011 The reproduction, even partial of this document is forbidden without prior written agreement of MV Agusta S.p.A. Part. N°8A00B3258 - Edition N°3 Printed February 2011...
  • Page 3 Engine workshop manual MV AGUSTA BRUTALE - Brutale 990 R - Brutale 1090 RR...
  • Page 4 Statement This manual, to be used by the MV Agusta authorised workshops has been realised with the purpose of assisting authorised personnel in maintenance and repairs operations of the motorcycle. The knowledge of technical data herein noted, determines the complete professional training of the technician.
  • Page 5 General index GENERAL DESCRIPTION ..............Rev. 0 MAINTENANCE ................. Rev. 2 CYLINDER KIT .................. Rev. 1 CYLINDER BLOCK ................Rev. 2 LUBRICATION ................... Rev. 0 ELECTRICAL COMPONENTS ............Rev. 0 TIGHTENING TORQUES ..............Rev. 0 SPECIAL TOOLS ................Rev. 1 ANALYTICAL INDEX .................
  • Page 7 General description SECTION REVISION 0 - 1 -...
  • Page 8 General description SUMMARY HOW TO CONSULT THIS MANUAL ..................Page THE PURPOSE OF THIS MANUAL ..................Page GLOSSARYAND SYMBOLS ....................Page RIGHT HAND AND LEFT HAND STANDARD ................ Page SAFETY ..........................Page OBSERVATIONS ........................Page INDEX ............................ Page OPERATIVE TECHNICALSPECIFICATIONS ................. Page - 2 -...
  • Page 9 All information, instructions and technical data included in this manual are based upon information on the product updated at the moment of going to print. MV Agusta S.p.A. reserves the right to carry out changes at any moment without prior notice and without incurring any obligation.
  • Page 10 General description GLOSSARY AND SYMBOLS ATTENTION This signifies that the lack or During this kind of procedure the incomplete observance inflammable vapours might develop of this advice can be gravely and metallic parts might be expelled dangerous for your safety at high velocity.
  • Page 11 General description Supplies key information for the best All of the countersigns indicting right, left, NOTE fulfilment of the operation. superior, inferior, front and back, refer to the motor-bike in the normal direction of march. The motor supports numbering of the cylinders and of the attached components, increases moving from left towards right in regards to the direction of march.
  • Page 12 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 4 Cylinder 3 Cylinder 2...
  • Page 13 General description SAFETY The information contained in this paragraph is fundamental so that the operations ATTENTION carriedout on the motorcycle can be conducted with minimum risk to the mechanic. Carbon Monoxide • Exhaust gases contain carbon monoxide (CO) that is poisonous. Carbon monoxide can cause the loss of consciousness and death.
  • Page 14 General description Brake fluid • Brake fluid is extremely corrosive. • Avoid any contacts with the eyes, skin and the mucous membrane. • If brake liquid comes into contact with the skin, remove all contaminated clothing and wash immediately with soap and water.
  • Page 15 • Slackening or tightening nuts or screws, always start withthose of a greater dimension or from the centre. Alwaysrespect the torque values indicated. • Utilise only MV Agusta spare parts. INDEX GENERAL INDEX SUMMARY OF EACH CHAPTER...
  • Page 16 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 forks. 3) Homologation data 2) Engine registration number 1) Frame registration number Below is an example of the designation of the frame registration number: ZCG B5 10 AA ? V ??????
  • Page 17 Maintenance SECTION REVISION 2 - 1 -...
  • Page 18 Maintenance SUMMARY PLANNED MAINTENANCE SCHEDULE ................Page THROTTLE BODY ADJUSTMENT AND TUNING ..............Page - 2 -...
  • Page 19 At least once a year Substitution ..Engine oil filter (utilize only MV Agusta original oil filter) At every substitution of engine oil ..Check level / Top up Engine coolant .
  • Page 20 Maintenance Programmed maintenance schedule 1000 6000 12000 18000 24000 30000 36000 Km (ml) covered (600) (3800) (7500) (11200) (14900) (18600) (22400) pre- Service delivery Check Pinion wheel / Stop washer Substitution At least at each substitution of the transmission chain Check Crown wheel Substitution...
  • Page 21 Chain lubrication oil MOTUL CHAIN LUBE ROAD * To find the recommended product, MV Agusta suggests going directly to the authorised MV Agusta dealers. AGIP Racing 4T10W/60 has been manufactured for the F4 engine. If the described oil is not available, MV...
  • Page 22 Maintenance ITEM STANDARD WEAR LIMIT VALVES Ø Sealing external diameter +0,3 Exhaust..........24,6 +0,3 Inlet............ 28,6 +0,3 Sealing face thickness......Stem - Guide clearance Exhaust..........0,02 ÷ 0,04 mm......Coupling: 0,10 mm Inlet............ 0,01 ÷ 0.03 mm......0,08 mm Ø Guide internal diameter....4,5 mm......
  • Page 23 Maintenance ITEM STANDARD WEAR LIMIT CYLINDER AND PISTONS Piston ovalization................. 0,015 mm Piston-Cylinder play......0,038 ÷ 0,067 mm..... 0,10 mm Piston-Pin play........0,004 ÷ 0,012 mm..... 0,03 mm Wrist pin-Connecting rod clearance.. 0,015 ÷ 0,032 mm..... 0,06 mm Piston ring width -0,01 segment.........
  • Page 24 Maintenance ITEM STANDARD WEAR LIMIT GEAR SHIFT Gear fork - Groove pivot play....0,35 ÷ 0,15 mm......0,65 mm Shift drum groove width......7,05 ÷ 7,15 mm......7,35 mm Ø Fork pivot..........6,8 ÷ 6,9 mm......6,7 mm Minimun idle gear axial play....0,10 mm Maximum gear fork play......
  • Page 25 Maintenance Cleaning the parts All of the parts must be cleaned with special biodegradable solvents and dried with compressed air. Proceed with the cleaning process of all the parts before disassembling them as well as after the particular parts have been disassembled. Clean each part even before reassembling.
  • Page 26 Maintenance Measuring compression in the cylinder The following tools are necessary in order to carry out this procedure: Spark plug key: n°800089013 Compression measurer Adapter for the compression measurer. A) Heat the motor to the usual functioning temperature (of regime); B) Switch off the engine, remove the tank, air box and spark plugs;...
  • Page 27 Maintenance THROTTLE BODY ADJUSTMENT AND TUNING (Tickover check, CO synchronisation and check) Check and adjust First 1000 kilometres and then every 6000 kilometres The throttle body adjusting should be performed starting the engine of the motorcycle, therefore you should use a flue gas exhauster in order to not saturate the environment with burnt gas.
  • Page 28 Maintenance Adjustment and calibration of throttle body After connecting the diagnostic software to the central unit, before starting the engine check the position of the throttle valve: 2.3 degrees (min. 1.7, max 2.9). If it does not fall within the range, use the TPS feature to reset it, WITHOUT TOUCHING THE MECHANIC ADJUSTING SCREW OF THE THROTTLE.
  • Page 29 Maintenance channel (mvolt), which was next to zero, will start to rise. After starting the Lambda control (Lambda % range), the Lambda (mvolt) will range between a high of 1000 mvolt and a low of 0 mvolt (minus the diagnostic software lag). To see the range more clearly, adjust the two graphic settings.
  • Page 30 Maintenance To do this proceed in the following way: If the “lead correction” channel is NEGATIVE, close the by-pass valves to take air out, keeping it aligned until the “Lead correction” setting goes to work within a range of -4°to +4°. If the “Lead correction” channel is POSITIVE, open the by-pass valves to add air, keeping it aligned until the “Lead correction”...
  • Page 31 Cylinder kit SECTION REVISION 1 - 1 -...
  • Page 32 Cylinder kit SOMMARIO CYLINDER HEAD ......................PAGE 3 DISTRIBUTION CONTROL UNIT ................... PAGE 7 CYLINDER AND PISTON GROUP ................. PAGE27 - 2 -...

  • Page 33: Cylinder Head

    Cylinder kit CYLINDER HEAD Tghtening torque Thread blockers medium medium sealant Apply motor oil NO OIL Do not apply neither oil nor other types of substances Apply grease Apply silicone sealing Apply HSC Molikote Apply mastic for gaskets - 3 -...
  • Page 34 Cylinder kit Removal of Head group Remove the eight tightening nuts (1) and remove the valve cover (2) proceed carefully so as not to damage the gasket (3). When refitting, it is essential to apply silicon sealant as shown in the figure at the beginning of the chapter.
  • Page 35 Cylinder kit Remove the oil tube adduction and the head situated at the front of the motor, using the two tightening screw with a T number 8 key. Working on the phonic wheel knot with a number 19 mm bush key rotate the drive shaft up to the point where the n°1 piston is at MSP in burst phase.
  • Page 36 Cylinder kit DISTRIBUTION CONTROL UNIT Tightening torque Thread blockers strong medium Apply motor oil NO OIL Do not apply neither oil nor other types of substances Apply grease Apply silicone sealing Apply HSC Molikote Apply mastic for gaskets - 6 -...
  • Page 37 Cylinder kit Chain tensioner Remove the central screw-cap and withdraw the spring and the pin. Remove the screws fixing the chain tensioner to the head. Remove the chain tensioner. Disassembly the chain tensioner and check the correct working of each part.
  • Page 38 Cylinder kit Removing the valve gear components First remove the 2 external stands (4and 5) of the camshafts by means of the four screws each internally hexagonal. At the same time remove the 2 internal stands (6 and 7) placing attention on the thrust caused by valvesprings.
  • Page 39 Cylinder kit Remove the 12 tightening nuts from the head beginning from the external ones proceeding towards the internal ones, following the sequence indicated in the figure. On each stud bolt there is a washer. Be carefully no to let it fall into the motor, you may block the holes with clean rags.
  • Page 40 Cylinder kit Remove the head and place it onto a clear place. Remove the gasket which will be substituted during reassembly. Avoid placing the head upside down. Inspection of the head group Remove carbon deposits from the combustion chambers. Clean away eventual encrustments from the canalizations of the cooling liquid.
  • Page 41 Cylinder kit Head assy assembly To execute this operation you need the following 32 Nm special tool: A) n° 8000A3406 piston / cylinder plane distance measuring tool Place the new gasket on the cylinder plane. The gasket is of the same thickness of the one installed before if no parts replacement occurred.
  • Page 42 Cylinder kit Insert the centering bushes between the head and the cylinder. Fit the gasket with the inscriptions facing up and the protrusion towards the march gear. Positioning the head. Insert the washers on the stud bolts if necessary with the help of a screw driver to guide them onto the internal stud bolts.
  • Page 43 Cylinder kit DISTRIBUTION GEAR AND DRIVING SHAFT TIMING Check and placement of distribution chain At each motor revision verify the wear state of each transmission distribution component. If the gear teeth appear to be very worn substitute each piece. Substitute the chain at the foreseen mileage. In case wear should result beyond the permitted allowance even of just one of the distribution components, check them all and...
  • Page 44 Cylinder kit Pin number 1 Pin number 24 Pin number 25 - 14 -...
  • Page 45 Cylinder kit CAMSHAFT AND DRIVING SHAFT TIMING Continue with the setting as follows: be sure that piston n°1 is the MSP in burst phase; in this position “T” notch on the phonic wheel is in line with the reference notch on the bedplate. Remove the copper thread from distribution chain, keep the chain tightened.
  • Page 46 Cylinder kit Position the n° 2 and n° 3 stands, referring to the numbers towards the inlet end; Position the n° 1 and n°4 stands, Progressively move the internal hexagonal screws close. Tighten the screws at a torque of 12 Nm, always beginning from n°...
  • Page 47 Cylinder kit Dismounting cylinder head pieces In order to carry out this procedure the following tools 800095179 are necessary:tool n°800094796 to disassemble valves tool n°800095179 to remove semi cones tool n°800094798 to take out rubber holdings Each piece relative to the same valve (cup, spring, semi-cone, etc.) must be reassembled onto the same valve from which it came off.
  • Page 48 Cylinder kit Then remove in the following order: A) Semicones B) The 2 coaxial springs (4 and 5); C)If necessary remove the rubber holdings using tool n°800094798 D)Remove the inferior disk more grazingly (6) E) Slide the valve out of the combustion chamber. 800094798 - 18 -...
  • Page 49 Cylinder kit Maintenance of the valve slot Check the stroke surface [A] between the valve [B] and the slot [C] : no traces of pitting or cracks must appear. Measure the external diameter [D] of the stroke surface on the valve slot. If this should appear to be too elevated it is possible to repair the slot.
  • Page 50 Cylinder kit Substitution of the valve slot The following tools are necessary for this procedure: prick-puncher n°800095319 for inlet slot prick-puncher n°800095318 for exhaust slot Proceed as follows: A) Remove the worn slots carefully milling them so asnot to damage the head lodging B) Check the lodging diameter on the head and choosethe oversized valve slot considering that the assem-bling interference should be 0,10÷0,15 mm.
  • Page 51 Cylinder kit Valve guide check and maintenance In order to carry out this procedure the following tools 800095429 are necessary: Control tampon n°800095429 Tampon n°8000A2385 valve stem-valve guide play: 0,01÷0,03 mm inlet 0,02÷0,04 mm exhaust coupling limit : 0,08 mm inlet 0,1 mm exhaust internal guide Ø...
  • Page 52 Cylinder kit Guide valve installation Assemble an oversized valve guide as follows: Oil the external valve guide surface. Slowly and evenly heat the cylinder head up to 150°. If necessary cool the valve guides with (N2) nitrogen liquid; or dry ice. Insert the valve guide using the special n°8000A2385 tampon up to the stroke and let rest until the tempera- ture has stabilized.
  • Page 53 Cylinder kit Valve-guide valve coupling Coupling play at assembly must be: 0,01 ÷0,03 mm inlet 0,02 ÷0,04 mm exhaust The maximum coupling limit permitted is even to 0,08 mm inlet 0,10 mm exhaust If a major play should result, substitute valve and valveguide.
  • Page 54 Cylinder kit Assembling the valve. Insert in the order of: A) Insert the two coaxial springs B) Slide the semi cones into the superior disk slot and thus place the disk on the springs C)Assemble the head on the disassembling valve tool n°...
  • Page 55 Cylinder kit Regulating valve play Verify that the spark plugs have been disassembled. Should this procedure be carried out with the head assembled on the motor, block the spark plug holes with clean rags and assemble platen° 800094797 to avoid the pieces accidentally falling into the chain distribution opening.
  • Page 56 Cylinder kit CYLINDER AND PISTON GROUP Tightening torque Thread medium Apply motor oil NO OIL Do not apply neither oil nor other types of substances Apply grease Apply silicone sealing Apply HSC Molikote Apply mastic for gaskets - 26 -...
  • Page 57 Cylinder kit Removing cylinder and pistons Remove the cylinder head and rubber connecting rodbetween the cylinder and water pump as described inthe relative paragraphs.Carefully slide out the cylinder group being careful notto damage the elastic strips.Work on one piston at a time to continue the removal.First remove the 2 pistons which are at the MSPandrotate the drive shaft at 180°and disassemble the 2remaining pistons.
  • Page 58 Cylinder kit Cylinder revision Check to be sure that enclosures show no sign of seizures with the pistons. Check piston ovalization in the following way: A) Measure the nominal diameter of each cylinder at a distance of 20 mm from the superior edge as indicated in the figure.
  • Page 59 Cylinder kit Piston-cylinder coupling The cylinder-piston groups are furnished already coupled; if there should be an exchange of cylinders and pistons between them it would be necessary to proceed surveying coupling plays. Measure the diameter of the (ND) pipe at 20 mmfrom the superior plane, as indicated on the sketch.
  • Page 60 Cylinder kit Piston-pin connecting rod foot coupling Play between piston pin and connecting rod foot must be of 0,015÷0,032 mm. Maximum wear limit allowed 0,06 mm. Segments Verify the absence of lines and traces of shrinkage on each segment. Verify that the edge of the segment is well defined and free in the segments.
  • Page 61 Cylinder kit Cylinder and piston assembly The segments must be assembled on the piston with the writing “R” “RN” turned upwards and by following the outline in the figure. Assemble the internal ring on the piston Insert the pistons complete with segments on the connecting rods with the arrow facing the exhaust Insert the piston pins into the piston until beat.
  • Page 62 Cylinder kit Position the two pistons 1 and 4 at the MSP turning the drive shaft. First insert the two pistons at the MSP, thus rotate thedrive shaft at 180°to invert the piston positions and toinsert the two remaining ones. Insert the pistons by manually pushing down on the segments.
  • Page 63 ENGINE BLOCK SECTION REVISION 2 - 1 -...
  • Page 64 ENGINE BLOCK SUMMARY CLUTCH ......................... PAG. 3 GEAR AND GEAR CONTROL ..................PAG. 16 WATER PUMP ........................ PAG. 24 STARTING........................PAG. 27 CRANKCASE ......................... PAG. 32 CAPS ..........................PAG. 33 CRANKSHAFT ....................... PAG. 46 COUNTERSHAFT ......................PAG. 48 - 2 -...
  • Page 65 ENGINE BLOCK Tightening torque Threadblockers medium Do not apply neither oil nor other types of substances Apply motor oil NO OIL Apply grease Apply silicone sealing Apply HSC Molikote Apply mastic for gaskets - 3 -...
  • Page 66 ENGINE BLOCK The clutch release occurs using a post poning return group composed of a small thrust piston placed on the left side of the motor and operated by a hydraulic system. This small piston pushes a command rod which makes the disk pusher plate function.
  • Page 67 ENGINE BLOCK Manually remove all of the attrition disks (3) that you can. (procedure for BRUTALE - Brutale 990 R) Subsequently straighten the nut washer. Unscrew the nut using tool n°800079015 to hold the clutch hup still and remove it.
  • Page 68 ENGINE BLOCK (procedure for B4 1090) Unscrew the nut using tool n°800079015 to hold the clutch hub still and remove it. Remove the spacer and the springs. Extract the clutch hub. - 6 -...
  • Page 69 ENGINE BLOCK Remove the flange. (standard procedure) Remove the washer (1) and the (2) clutch housing. Remove the spacer (3) and the shim washer (4). - 7 -...
  • Page 70 ENGINE BLOCK Disassemble the clutch group following the sequence inthe figure. - 8 -...
  • Page 71 Put the plate on a table and check the deformation. The maximum limit of deformation is 0,1 mm. Measure the length “L” of the springs with a gauge. Service limit: BRUTALE - Brutale 990 R 52,5 mm Brutale 1090 RR 39 mm Replace the springs exceeding the service limit.
  • Page 72 Position the rounded corner on the engine side. (Procedure for BRUTALE e Brutale 990 R) Assemble the disk-holding hub by first mounting the “5” piece (see CLUTCH fig.), then the “4”...
  • Page 73 ENGINE BLOCK three different types of sealed disks are used: firstly insert the disk with the greater internal diameter (1), then the 8 equally sized disks (2), alternating the smooth disks. Finally insert the external disk (3) with the larger cells of friction material.
  • Page 74 ENGINE BLOCK Assemble the disk pusher plate tightening the screws with springs as 10 Nm. Procedure for B4 1090 Install the flange with the six columns, already assembled (torque 4.5 Nm). Fit in the disk-holder and angle it so the bearings fit into their housing on the flange.
  • Page 75 ENGINE BLOCK Use the tool no. 800079015 to lock the clutch bell, thentighten the nut to 140 Nm. Notice: three types of packed disks are used; to assemble them, see the diagram below. First fit in one of the two disks (1) with the larger friction cells and a plain disk (3).
  • Page 76 ENGINE BLOCK Fit in the clutch dish pusher, the six spring holders, The spring supports have an edge with a NOTE concave segment which must be oriented towards the center of the clutch plate pusher; for correct assembly refer to the scheme below. the plates, the springs, the self-centring washers and the screws;...
  • Page 77 ENGINE BLOCK Finally, take a gauge and check if the measured distance between the outer surface of the disk pusher and the packed disk is consistently 5 ±0.2 mm in the four holes. (Standard procedure) Replace the cover seal lining up with the centering pins.
  • Page 78 ENGINE BLOCK GEAR AND GEAR CONTROL Tightening torque (M8) Thread blockers medium medium Do not apply neither oil nor other types of substances Apply motor oil NO OIL Apply grease Apply silicone sealing Apply HSC Molikote Apply mastic for gaskets - 16 -...
  • Page 79 ENGINE BLOCK Gear group disassembling Remove the clutch following the instructions in the relative paragraph. Remove the clutch rod from the clutch end. Remove the 6 tightening screws from the gear cap. Using a rubber hammer, delicately beat on the primary shaft from the clutch end holding a hand on the gear cap until it moves from the crankcase.
  • Page 80 ENGINE BLOCK Gear control If necessary, disassemble the gear command group following the order shown in the figure. Place the various components in an orderly way so as to facilitate reassembling. Check each component for wear of irregular traces on its surface.
  • Page 81 ENGINE BLOCK Primary and secondary shaft Check the two shafts separately so as to avoid confusion of similar components. Place the components in such a way as to facilitate the correct positioning during reassembly. Check that the gear teeth are intact and the threads and grooves of the shafts are in perfect condition - 19 -...
  • Page 82 ENGINE BLOCK Gear group revision 8A0094792 In order to carry out the following procedure the following special tool is necessary: Motor simulation utensil n°8A0094792 Disassemble the gear group from the motor and reas- semble it on the special utensil n°8A0094792 motor simulator being careful to tighten the pinion fixing nuts with the separator that simulates the clutch hub and the 3 fixing screws on the plate.
  • Page 83 ENGINE BLOCK Replacement of gear shafts If it becomes necessary to replace one or both of the gear shafts, either wholly or in part, proceed as follows: A) firstly insert the main shaft with spindle and the relative fork in the gear plate; B) assemble the gear plate on the engine simulation tool by tightening the 3 screws, assemble the spacer which simulates the clutch assembly and...
  • Page 84 ENGINE BLOCK Reassembly Reassemble the components on the plate in the reverse order compared to disassembly. Rimontare i componenti sulla piastra seguendo l’ordine inverso rispetto allo smontaggio. Assemble the shafts and the desmo on the plate, - 22 -...
  • Page 85 ENGINE BLOCK assemble the gear group on the n°8A0094792 engine 8A0094792 simulation tool. Install a shift pedal and check the gearbox is correctly working. All the gears must be inserted and uninserted without stumbling. In case of stumbling, verify that the axial play has been correctly restored.

  • Page 86: Water Pump

    ENGINE BLOCK WATER PUMP Tightening torque Thread blockers medium Do not apply neither oil nor other types of substances Apply motor oil NO OIL Apply grease Apply silicone sealing Apply HSC Molikote Apply mastic for gaskets - 24 -...
  • Page 87 ENGINE BLOCK Water pump removing The engine does not need to be removed from NOTE the frame to perform this operation Work with cold motor. Drain liquid. A) Loosen the clamp and remove the coupling from the cylinder group, being careful not to damage it and drain the cooling liquid by removing the screw (B) B) Remove the screws (1) which fasten the pump body to the crankcase.
  • Page 88 ENGINE BLOCK Water pump reassembly Grease the O-Ring and its housing on the pump evenly. Make sure the grooves on the spindles of the water pump and the oil pump run in the right direction. A) Insert the pump on the crankcase being very careful not to damage the O-Ring on the pump body and maintaining the cable of the gear sensor around the pump body as shown.
  • Page 89 ENGINE BLOCK STARTING Tightening torque Thread blockers medium strong Do not apply neither oil nor other types of substances Apply motor oil NO OIL Apply grease Apply silicone sealing Apply HSC Molikote Apply mastic for gaskets - 27 -...
  • Page 90 ENGINE BLOCK Freewheel starting Remove the clutch and gear indicated in the relativeparagraphs.Remove the screw (1) and the plate which fixing the intermediate gear-pin. Slide out the intermediate starting gear-pin and the intermediate gear. Undo the 7 fixing screws and remove the cover of the alternator and the relative gasket.
  • Page 91 ENGINE BLOCK Extract the flywheel using tool cod.8000B4305. Remove the 3 fixing screws and remove the stator by pulling the cable tray rubber away from the engine block. Remove the 4 fastening screws (2) on the starter flange and the cable guide plate. Manually extract the starter assembly.
  • Page 92 ENGINE BLOCK Take the assembly apart and check that its components are intact. Check that the surface of the spring drive rubber is even and does not have any cracks; otherwise replace. Check the condition of the free wheel. Reassembly Evenly grease the rubber and its gear housing and the outer ring of the free wheel.
  • Page 93 ENGINE BLOCK Assemble the stator and tighten the 3 fastening screws to 6÷8 Nm with a medium strength thread- locking compound. 6÷8 Nm Insert the rotor and the locking tool cod.8000B4304, assemble the washer and the nut and tighten to a 65 Nm torque of 65 Nm with strong thread-locking compound.
  • Page 94 ENGINE BLOCK CRANKCASE Tightening torque 10+45° 10+40° Thread blockers medium medium Apply motor oil NO OIL Do not apply neither oil nor other types of substances Apply grease Apply silicone sealing Apply HSC Molikote Apply mastic for gaskets - 32 -...
  • Page 95 ENGINE BLOCK COVERS Tightening torque 40÷45 Thread blockers medium Do not apply neither oil nor other types of substances Apply motor oil NO OIL Apply grease Apply silicone sealing Apply HSC Molikote Apply mastic for gaskets - 33 -...
  • Page 96 ENGINE BLOCK Oil sump After having removed the oil filter (see Section E), emove the oil sump by unscrewing the 6 mm fixingscrews. Replace the gasket if necessary. Remove the two fixing screws and extract the oil filter support from the engine block. Remove the retaining spring and take out the oil suction filter.
  • Page 97 ENGINE BLOCK Remove the oil pressure adjustment valve (A) Disassemble the valve by removing the snap ring and check its components, accurately cleaning the mobile parts and the pipe. If the perfect working order of the valve is uncertain, replace with a new valve. Check that the oil filter support is intact.
  • Page 98 ENGINE BLOCK If the oil drip tube (1) was previously removed, re- assemble with the evenly greased seal rings, push into place with a rubber spacer. Assemble the filter support on the engine block, taking care not to spoil the seal rings. Accurately degrease the thread of the two screws and apply loctite 243, tightening to 10 Nm.
  • Page 99 ENGINE BLOCK Grease the holes and insert centering pins in the oil sump. When assembled in the sump, the bushes NOTE protrude more than in the engine block making it easier to centre before the sump comes into contact with the o-ring of the filter support, thus preventing the risk of damage.
  • Page 100 ENGINE BLOCK Crankcase disassembly Remove the oil filter, the sump and the oil filter support. Remove as follows as indicated in the relative paragraphs: A)The head B) The cylinder group C) The pistons D) The clutch E) The gear. Remove: F) The retaining plate (A), the relative screws and the two retaining screws (B) on the primary flange of the bearing on the lower block.
  • Page 101 ENGINE BLOCK H) Separate the two carters (1 and 2) by manipulatingthe protrusions I) If necessary remove the bearings (3). L) Slide the countershaft. M)Slide the main shaft out. - 39 -...
  • Page 102 ENGINE BLOCK (Procedure for BRUTALE) In the eventuality that the piston's oil nozzles should be removed it is recommended to manually extract them in order to avoid the damage of the ducts When reassembling it is necessary to clean NOTE the seats and the relative oil ducts of the carter from possible traces of dirty (Procedure standard)
  • Page 103 ENGINE BLOCK Reassembly Carefully degrease and clean from any paste residues. Position the bushings into the carter without lubricating. After having positioned them put oil on each bush. Laterally lubricate the n°5 support (both sides) as it carries out the function of the motor shaft centering. Put the new caps on the right side.
  • Page 104 ENGINE BLOCK Assemble the mainshaft and the counter shaft in such a way that the markings on the respective gears are perfectly aligned. (Procedure for BRUTALE) Lubricate the seal rings and insert them in the respective seats, preventively cleaned, of the oil ducts to starting (Á.) and to pistons (B).
  • Page 105 ENGINE BLOCK (Procedure for standard) Verify with a thick meter that the motor shaft has an axial play of 0,2 mm as regards the bench bearings. In case there should be different values contact the manufacturer. If it becomes necessary to disassemble the gear lubrication tube, reassemble, keeping the groove facing upwards.
  • Page 106 ENGINE BLOCK Spread a layer of the 1215 THREEBOND type garnish on the stroke points of the two semi-carters having attention to prevent the paste from coming into contact with the bushings and the central area of the oil passage. Couple the two semi carters carefully beating them with a plastic hammer until completely closed.
  • Page 107 ENGINE BLOCK Manually drive the M8 and M6 screw without tightening. All screws have either an equal or visibly NOTE different length; it is therefore impossible to mix them up during reassembly. Tighten the screws of the engine block, following the Screw Nr.
  • Page 108 ENGINE BLOCK (Procedure for BRUTALE) Oil nozzles to pistons Clean the seats of the seal rings on the nozzles from possible traces of dirt. Alw ays replace the seal rings before reassembly lubricate the seal rings with oil and insert on the nozzles.

  • Page 109: Mainshaft And Countershaft

    ENGINE BLOCK MAINSHAFT AND COUNTERSHAFT Tightening torque 50(*) Thread blockers medium (*); See assembling instructions Do not apply neither oil nor other types of substances Apply motor oil NO OIL Apply grease Apply silicone sealing Apply HSC Molikote Apply mastic for gaskets - 47 -...
  • Page 110 ENGINE BLOCK Connecting rod disassembly Remov e the crankshaft following the prescribed procedure. Position the main shaft with the connecting rods oriented downwards. Loosen the bolts that tighten the head of connecting rod. Remove the two bolts sustaining the connecting rod stem.
  • Page 111 ENGINE BLOCK Coupling semi bearings-connecting rod pin If no substitutions have been made it is sufficient to verify the connecting rod measurement and its pins and refer 120° to the chart included, choose the semi bearings according to the colour. - Connecting rod pin The measure of the roundness of the crank pin must be performed along the center surface of the crank...
  • Page 112 ENGINE BLOCK Assembling half-bearings Fit the half-bearings into the big end of the connecting rod. • Degrease the screws and the connecting rod. • Apply oil only to the internal thread. • Fasten and make sure the length of the screws is between 0.20 mm and 0.22 mm with a minimum torque of 50 Nm •...
  • Page 113 Lubrication SECTION REVISION 0 - 1 -...
  • Page 114 Lubrication SUMMARY OIL PUMP ..........................PAGE LUBRICATION COMPONENTS: OIL RADIATOR ..............PAGE LUBRICATION COMPONENTS: HEAD DELIVERY CONDUCT ..........PAGE LUBRICATION COMPONENTS: OIL TUBING SUPPORT PLATE ........PAGE 10 OIL FILTER REPLACEMENT ....................PAGE SCHEMA LUBRIFICAZIONE ....................PAGE 14 - 2 -...
  • Page 115 Lubrication LUBRICATION Tightening torque 18÷20 Thread blockers medium medium sealant Do not apply neither oil nor other types of substances Apply motor oil NO OIL Apply grease Apply silicone sealing Apply HSC Molikote Apply mastic for gaskets - 3 -...
  • Page 116 Lubrication Pompa olio Remove the clutch and the gear as described in the relative paragraphs. Remove the seeger and the oil pump gearing. Remove the 3 tightening screws. Push the oil pump shaft from the gear end and slide the oil pump body from the clutch end. - 4 -...
  • Page 117 Lubrication The oil pump does not require maintenance. NOTE Do not take the oil pump apart. Any attempts to take the components of the water pump apart will invalidate the guarantee. If necessary, replace the oil pump with a new oneavailable to rechange Grease evenly the gasket and put into its seat (prevently cleaned and degreased) on the oil pump.
  • Page 118 Lubrication LUBRICATION COMPONENTS: OIL RADIATOR Disassembling undo the fixing screws and remove the plates which retain the hoses to support plate. Disconnect the radiator-engine anchoring rod (1) and, sustaining the radiator, slide the hoses out of the support plate. - 6 -...
  • Page 119 Lubrication Rimontaggio If the pipes and connectors were removed from the radiator, replace them carefully by placing a wrench on the radiator to prevent the connectors of the radiator from tearing. Lubricate the threading of the connectors with engine oil. Tighten the pipes and connectors at the prescribed torque.
  • Page 120 Lubrication Once inserted the nipples of delivery tubes into their seats on the support plate, mount the retaining plates and tighten the screws to a torque of 10 Nm. 10 Nm Reassembly the anchoring rod with the rubbers on the pin and insert the radiator’s pins on it - 8 -...
  • Page 121 Lubrication LUBRICATION COMPONENTS: Head delivery conduit Disassembling Remove the two fixing screws and the plates which retain the head delivery oil pipe Slide the head delivery. Reassembly Verify the O-rings placed on the oil head delivery conduit for wear and substitute them, if necessary. When reassembling, grease both O-rings and position the upper part of the conduit in the seat arranged within the head and the lower part of the...
  • Page 122 Lubrication LUBRICATION COMPONENTS: OIL TUBING SUPPORT PLATE Disassembling Undo the five fixing screws and remove the plate When reassembling, clean accurately the surfaces of the oil piping support plate. Verify the two O-rings placed in the back part of the oil tubing support plate for wear and substitute them, if necessary.Grease the O-rings before reassembling the plate.
  • Page 123 Take the oil filter out from the new engine oil filter kit Oil filter kit: Part. Code 8000B3439 Use only original components of MV Agusta. Loosen the four screws of the oil filter cover Remove the four screws applying a light pressure on the cover in order to oppse the spring action.
  • Page 124 Lubrication Lubricate the gasket on the filter with engine oil. Insert the filter in its seat. Lubricate evenly the seal ring with grease and mount it in its seats on oil filter cover. - 12 -...
  • Page 125 Lubrication Mount the oil filter cover maintaining it in beat with the sump and insert the screws by hand. Tighten the four screws to a torque of 10 Nm. 10 Nm Clean the oil discharge plug from possible metal residues and degrease accurately the thread. When reassembly use a new sealing washer (1) available to rechange.
  • Page 126 Lubrication In the scheme below are indicated the components of the lubricating circuit and the oil run Starting Camshafts bearing Free Alternator wheel cooling circuit Main bearing Gearshafts Gear bearing Intermediate gear Connecting rod bushing Countershaft bushing To Gear command Bench Over pressure bushing...
  • Page 127 Electrical components SECTION REVISION 0 - 1 -...

  • Page 128: Electrical Components

    Electrical components ELECTRICAL COMPONENTS ....................PAGE - 2 -...
  • Page 129 Electrical components ELECTRICAL COMPONENTS Tightening torque Thread blocker medium medium medium medium medium Apply motor oil NO OIL Do not apply neither oil nor other types of substances Apply grease Apply silicone sealing Apply HSC Molikote Apply mastic for gaskets - 3 -...
  • Page 130 Electrical components Engine oil temperature sensor Remove the connector and check (with the engine off) that there is no continuity between the pole of the sensor and the engine mass. Otherwise, replace the sensor. Apply a medium strength thread-locking compound on the thread of the sensor and tighten to a torque of 22 Nm.
  • Page 131 Tightening torques SECTION REVISION 0 - 1 -...

  • Page 132: Tightening Torques

    Tightening torques TIGHTENING TORQUES ....................... PAGE - 2 -...
  • Page 133 Tightening torques TIGHTENING TORQUES TABLE DESCRIPTION Thread blockers HEAD Camshaft and gear screws strong Sliding block distribution screws medium Stand screws Valve cap and Reed cover screws Head tightening nuts 50 (35+15) Chain tightening screws Exhaust pipes stud bolts Spark plug coil screws Chain tightening cap CLUTCH Clutch nut...
  • Page 134 Tightening torques TIGHTENING TORQUES TABLE DESCRIPTION Thread blockers CRANKCASE M6 clutch cover screws M6 starting bearing screw medium M6 main bearing screw medium M8x80mm fixing screws 10+ 45° M8x50mm fixing screws 10+ 40° M8 fixing screws Plate screws for oil radiator connectors Inlet/outlet connectors for radiator oil medium CONNECTING ROD...
  • Page 135 Service tools SECTION REVISION 1 - 1 -...
  • Page 136 Service tools - 2 -...
  • Page 137 Service tools Code Q.ty Note B4 990R B4 1090RR DESCRIPTION 8A0094792 • • CHANGE GEAR ASSEMBLY TOOL 800086119 • • DOWELBUSH 8000A1087 • • BEARING 800098405 • • BEARING 800087300 • • BEARING 8A00A5394 • • DIAGNOSTIC SOFTWARE 8000A3406 • •...
  • Page 138 Service tools - 4 -...
  • Page 139 Service tools Code Q.ty Note B4 990R B4 1090RR DESCRIPTION 8000A2281 • • TIMING CHAIN CUTTING TOOL 8000A2280 • • TIMING CHAIN MOUNTING TOOL 800079015 • • CLUTCH BLOCKING TOOL 800095318 • • PAD FOR EXHAUST VALVE SEAT 800095319 • •...
  • Page 140 Analytical index SECTION REVISION 0 - 1 -...
  • Page 141 Analytical index ANALYTICAL INDEX WORKSHOP MANUAL BRUTALE - Brutale 990R - Brutale 1090RR Sez. A - General description Glossary and symbols ........A- 4 How to consult this manual ......A- 3 Index ..............A- 9 Observations ............ A- 9 Operative technical specifications ....

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