MV Agusta Brutale 990 R Workshop Manual
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MV Agusta Brutale 990 R Workshop Manual

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Summary of Contents for MV Agusta Brutale 990 R

  • Page 2 © 2010 The reproduction, even partial of this document is forbidden without prior written agreement of MV Agusta S.p.A. Part no. 8A00B3256 - Edition no. 2 Printed – July 2010...
  • 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 Freni General Index GENERAL DESCRIPTION..................Rev. 0 MAINTENANCE ......................Rev. 1 BODYWORK ......................Rev. 1 AIR INTAKE INJECTION SYSTEM ................Rev. 0 ELECTRICAL SYSTEM .................... Rev. 1 SUSPENSION AND WHEELS .................. Rev. 1 FRAME ........................Rev. 1 BRAKES........................Rev. 1 COOLING SYSTEM AND LUBRICATION SYSTEM..........
  • Page 7 General description SECTION Revision 0 - 1 -...

  • Page 8: Table Of Contents

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

  • Page 9: How To Consult This Manual

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

  • Page 10: Glossary And Symbols

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

  • Page 11: Right Hand And Left Hand Standard

    General description RIGHT HAND AND LEFT HAND STANDARD In order to specify the right/left convention used within the chapters of this manual, see the following motorcycle and engine scheme where all sides which refer to are reported. Cylinder 3 Cylinder 2 Cylinder 4 Cylinder 1 Right side...

  • Page 12: Safety

    • Used oil contains dangerous substances and poisonous for the environment. To substitute oil, it is recommended to go to an authorised MV Agusta dealer who is equipped to deal with the collection of used oil in respect of the norms in force.
  • Page 13 • The battery contains dangerous substances that are poisonous for the environment. It is advisable to substitute it at an MV Agusta dealer that is equipped to dispose of this product in respect of the norms in force. • Do not dispose of used batteries in the environment.

  • Page 14: Warning

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

  • Page 15: Operative Technical Specifications

    General description OPERATIVE TECHNICAL SPECIFICATIONS MOTORCYCLE IDENTIFICATION Frame registration number Engine registration number Homologation date The registration number of the motorcycle is stamped on the right side of the steering head. The engine part number is stamped on the top half casing near the fork. 3) Homologation date 2) Engine registration number 1) Frame registration number...
  • Page 16 General description - 10 -...
  • Page 17 Maintenance SECTION Revision 1 - 1 -...
  • Page 18 Maintenance SUMMARY TECHNICAL INFORMATION ............PAGE 3 TECHNICAL DATA .

  • Page 19: Technical Information

    Maintenance TECHNICAL INFORMATION 2093 1438 TECHNICAL DATA Description BRUTALE 990 R BRUTALE 1090 RR CHARACTERISTICS Wheelbase (mm) (*) 1438 1438 Total length (mm) (*) 2093 2093 Maximum width (mm) Seat height (mm) (*) Ground clearance (mm) (*) Trail (mm) (*)
  • Page 20 Maintenance TECHNICAL DATA Description BRUTALE 990 R BRUTALE 1090 RR TIMING Type D.O.H.C. radial valves D.O.H.C. radial valves LUBRICATION Type Wet sump Wet sump IGNITION – FUEL FEED SYSTEM Type Magneti Marelli 5.SM starter-injection system with Mikuni throttle body Induction-discharge electronic starter, “Multipoint” phased sequencial electronic injection...
  • Page 21 Maintenance TECHNICAL DATA Description BRUTALE 990 R BRUTALE 1090 RR ELECTRICAL SYSTEM Voltage 12 V 12 V Front dipped beam light bulb 12 V - 55 W 12 V - 55 W Front main beam light bulb 12 V - 55 W...

  • 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 Manutenzione Maintenance Programmed maintenance schedule 1000 6000 12000 18000 24000 30000 36000 Km (mi) covered (600) (3800) (7500) (11200) (14900) (18600) (22400) Pre- Service delivery Description Operation Transmission and flexible controls Check / Adjust Check / Adjust Transmission chain Lubricate Replace Check Front sprocket / stop washer...

  • Page 24: Maintenance And Tuning Operations

    MOTUL CHAIN LUBE ROAD – * : To find the recommended product, MV Agusta suggests going directly to the authorised MV Agusta dealers. AGIP Racing 4T 10W/60 has been manufactured for Brutale engine. If the described oil is not available, MV Agusta suggests using completely syn-...
  • Page 25 Maintenance To accede to the oil filter and the discharge and filling holes of the engine oil, it is necessary to carry out cer- tain operations beforehand: • Place the motorcycle on the rear stand. The substitution of the engine oil must N.B.
  • Page 26 Maintenance Remove the cover and take out the oil filter. Replace the oil filter and put the cover back on. On the oil discharge plug there is a magnet to attract any metal residues that could form in the engine during rotation.
  • Page 27 Maintenance Pour around 3 kg of engine oil (as specified in the table on page B-8) into the filling hole. Close the filler hole using the appropriate cap. Before replacing the filler cap, grease the O-ring (1) with silicone grease (see figure). Tighten the cap (2) to the prescribed tightening torque.

  • Page 28: Engine Coolant

    Maintenance ENGINE COOLANT Check/top-up level ¨ At the pre-delivery, at the first 1000 kilome- ters and then every 6000 kilometers Keeping the motorcycle in a vertical position, check that the level of engine coolant is between the «MIN» mark found on the expansion tank (1) and the lower part of the frame tube, that you can see from the open- ing on the frame protection panel on the left side of the motorcycle.
  • Page 29 Maintenance With the engine cold, top up the level using the filler hole of the expansion tank. Engine coolant substitution Substitution ¡ Every two years Before proceeding with the emptying of the system, perform the following operations in advance: • Remove the ignition switch cover (see “Engine coolant level check”);...

  • Page 30: Electric Fans

    Maintenance Check once again the level of the coolant inside the expansion tank (3). It should be between the «MIN» mark found on the expansion tank and the lower part of the frame tube, as shown in the figure. f the level is inferior to the «MIN» mark, top up the coolant level by pouring new coolant into the filler hole.

  • Page 31: Valve Mechanism Adjustment

    Maintenance VALVE MECHANISM ADJUSTMENT Check and adjust ¡ Every 12000 kilometers. The valve mechanism adjustment must be performed when the engine is cold. Remove in order the following components to carry out the measuring of the play between the camshaft and the valve cups: •...
  • Page 32 Maintenance Ensure that all the surfaces of the frame are protected by the application of the adhesive tape. Apply the same adhesive tape to the air intakes of the engine. Apply adhesive tape also on the oil breather tube (A) and on the terminals of the accelerator control (B).
  • Page 33 Maintenance Position the coils behind the tube frame so they do not get in the way of the subsequent disassembly opera- tions. Remove the secondary air blade from the head cover, only if inspection is necessary. Operating as shown in the figure, slightly lift up the cylinder head cover.
  • Page 34 Maintenance Remove the head cover gasket. To facilitate this operation, it is advisable to move the rubber engine coolant filling tube situated on the left side of the motorcycle. Complete the removal of the cylinder head cover by sliding it towards the rear part of the motorcycle. Remove the head cover gasket.
  • Page 35 Maintenance Proceed with the removal of the timing wheel cover by unscrewing the five fixing screws. Rotate the camshaft by turning the central nut in an anti-clockwise direction to bring piston N° 1 of the engine to the Top Dead Center position (T.D.C.) when the piston is at its uppermost part of the compression stroke.
  • Page 36 Maintenance Also the marks present on the toothed wheels of the camshaft must be aligned together when the timing wheel is in this position. Utilising a feeler gauge of the type shown in the figure, measure the play between the camshaft and the valve cups.
  • Page 37 Maintenance Carry out the measuring of the play of the following valves: Cylinders 1 and 2 intake valves (n° 1,2,3,4) Cylinders 1 and 3 exhaust valve (n° 11,12,15,16) Scrupulously, make a note of the order of the values measured in the form of a table. - 21 -...
  • Page 38 Maintenance For example, here is a hypothesis of a table in which are written the various values measured. Date Vehicle Engine registration n° Frame registration n° Kilometres travelled Values measured before substituting the valve cups: CYLINDER CYLINDER CYLINDER CYLINDER INDUCTION Valve n°...
  • Page 39 Maintenance The progressive numeration of each valve is illustrated EXHAUST in the photograph on the right. Note the anti-clockwise direction of the numeration. INTAKE To facilitate the operation, it is possible to note before- hand and in order the play values revealed on the strip of adhesive tape applied to the openings of the air intake conduits.
  • Page 40 Maintenance Check again the timing of the engine, ensuring that the incision stamped on the timing wheel is aligned with the “tooth” on the engine casing. Continue with the measuring of the play of the follow- ing valves: Cylinders 3 and 4 intake valves (n° 5,6,7,8) Cylinders 2 and 4 exhaust valves (n°...
  • Page 41 Maintenance Valve play between the valve cup and the cam Camshaft Upper cup for the springs Adjustment pad Valve cup Valve The play values measured between the valve cup and cam must be the following: For all intake valves 0,15 ÷ 0,24 mm For all exhaust valves 0,20 ÷...

  • Page 42: Spark Plugs

    Maintenance Timing chain, mobile timing chain guide and timing chain tensioner Timing chain and mobile timing chain guide: Check ¡ First 1000 kilometers Substitute ¡ Every 36000 kilometers Timing chain tensioner: Check/substitute ¡ Every 12000 kilometers 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 engine work- shop manual (Part.

  • Page 43: Fuel Filters

    Maintenance FUEL FILTERS Check and substitute ¡ Every 12000 km For the checking or substitution of the engine intake system filters (fuel filter, fuel pump filter), it is neces- sary to remove in sequence the following parts: • Passenger seat •...
  • Page 44 Maintenance Petrol flange assembly removal Close the tank filler cap. Turn the tank upside down and remove the eight screws (1) fastening the flange to the tank and the three spacers. Remove the flange assembly (2) from its seat. In this operation use a flat-headed screwdriver as illu- strated.
  • Page 45 Maintenance Extract the complete flange assembly (1). Disconnect the electric connectors of the fuel pump (1). Checking and replacing the O-Ring Check the condition of the O-Rings (1) which seal the flange (2). Make sure that the components are perfectly intact and lubricate with silicone grease.
  • Page 46 Maintenance During re-assembly, if the O-Rings have been repla- ced, lubricate surface lightly with silicone grease. The use of worn O-Rings can lead to a leaka- ge of petrol from the tank with a consequent risk of fire for the vehicle. Replacing the thermistor If the thermistor needs to be replaced, the cable clamp must be cut.
  • Page 47 Maintenance Take the thermistor out of its housing and replace with a new one. Reconnect the connector and fix a new clamp (Cod. 800056783). Replacing the filter cartridge If the filter cartridge needs to be replaced, it is first necessary to remove the lower clamp and take the tube out of the cartridge.
  • Page 48 Maintenance Remove the filter cartridge and replace with a new one. Insert the upper tube in the new cartridge and fix with a clamp taken from the new kit, using the special tool. Pneumatic pincer: Oetiker HO 3000 ME Insert the lower tube in the new cartridge and fix with a clamp taken from the new kit, using the special tool.

  • Page 49: Fuel Pump Assembly

    Maintenance FUEL PUMP ASSEMBLY - 33 -...
  • Page 50 Maintenance Fuel flange unit assembly Before starting the assembly of the flange to the fuel tank, check the condition of the two small overflow tubes connected to the lower part of the fuel filler cap. If these components are not in perfect condition, sub- stitute them and position the band fasteners as shown in the figure.
  • Page 51 Maintenance Position the flange unit (1) inside the fuel tank. Check that the two small overflow tubes (2) remain out- side of the fuel tank. Insert two CLIC R 96 105 band fasteners (1) onto the small tubes. Insert the two small rubber tubes (2) onto the appropriate spigot on the die-cast flange.

  • Page 52: Fuel Union Tube

    Maintenance FUEL UNION TUBE Check for leaks ¨ First 1000 kilometers and then every 6000 kilometers Carry out a visual check for eventual leakages from the fuel feed tubing and the unions (see figure). Substitute damaged parts if leaks or evaporation are found.
  • Page 53 Maintenance Insert the new fuel tube onto the union of the throttle body, until it has locked into place. UTILISE ONLY NEW PARTS. - 37 -...

  • Page 54: Throttle Body Adjustment And Tuning

    Maintenance THROTTLE BODY ADJUSTMENT AND TUNING (Tickover check, CO synchronisation and check) Check and adjust ¨ First 1000 kilometers and then every 6000 kilome- ters The throttle body adjusting should be performed start- ing the engine of the motorcycle, therefore you should use a flue gas exhauster in order to not saturate the environment with burnt gas.
  • Page 55 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: 2.35 degrees (min. 2, max 2.7). 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 56 Maintenance Twist off the plugs that close the vacuum tubes. The number of the cylinder to which the rubber plug is con- nected is written on the plug itself (A). The vacuum tubes are located on the right and left side of the vehicle.
  • Page 57 Maintenance To align the throttle body, use the diagnostic software. For the engine to work properly, adjust the throttle body so that the idling regime control works at “mid-range”. To do this, after finding the correct alignment, proceed as follows: If the “lead correction”...

  • Page 58: Air Filter

    Maintenance AIR FILTER Check/substitute Every 6000 kilometers Certain parts must be removed in sequence before acceding to the air filter. See chapter C “Bodywork”: • Passenger seat • Rider seat • Left tank side panel • Right tank side panel •...
  • Page 59 Maintenance Check the condition of the air filter. If it is necessary to substitute it, proceed as follows: Prepare a new air filter. Check that the inside of the air filter compartment is clean and free from foreign bodies. Insert the air filter complying with the correct assembly direction shown in the figure.
  • Page 60 Maintenance Before proceeding with the assembly of the air filter compartment onto the motorcycle, apply silicone grease to the gaskets of the air intake bell chambers. Proceed with the assembly of the parts listed below and according to the procedure described in chapter C “Bodywork”: •...

  • Page 61: Brakes And Clutch

    Maintenance BRAKES AND CLUTCH Check the levels of fluid in the systems¨ At pre-delivery, at first 1000 kilo- meters and then every 6000 kilo- meters Check for leakages¨ At pre-delivery, at first 1000 kilo- meters and then every 6000 kilo- meters Substitute fluid¨...
  • Page 62 Maintenance Before completing the operation, clean and wash accu- rately the 3 components of the chamber cover using alcohol and blow to dry them. Clean the edge of the fluid chamber with a clean cloth. Close the fluid chamber with the two relative screws. Imperfect cleaning of these parts could cause the discharge of small quantities of brake fluid during riding.
  • Page 63 Maintenance Check eventual leaks and blow-bys of brake and clutch fluid on the unions and tubing. If any breakages are seen, substitute the damaged parts as described in chapter H “Brakes”. Brake fluid leakages are dangerous and immediately discolour painted surfaces. Before riding, check the tubes and joints of the brakes for damage and signs of leaks.

  • Page 64: Brake/Clutch/Gearchange Commands Check

    Maintenance BRAKE/CLUTCH/GEARCHANGE COMMANDS CHECK It is possible to effectuate the adjustment of the posi- tion of the levers of the front brake, the clutch and also the gearchange lever. Such adjustments have been created to optimise the grip and the movement of the commands with regards to the needs of the motorcy- clist.
  • Page 65 Maintenance Gearchange/rear brake lever adjustment To carry out the adjustment of the rear brake lever and the gearchange lever, slacken the screw (1) utilising a 5 mm Allen key. Adjust the position according to the requirements of the rider utilising the same key and on the hexagonal hole (2).

  • Page 66: Brake Pads

    Maintenance BRAKE PADS Check/substitute ¨ At the first 1000 kilo- Front brake caliper meters and then very 6000 kilometers Check the condition and thickness of the brake pads on the calipers. Rear brake caliper Measure the thickness of the pad linings. If the thick- ness of the linings is equal or less than the wear limit shown below, replace the pads as described in chapter H “Brakes”.
  • Page 67 Maintenance After making adjustments, check that the throttle valves open slightly by activating the choke lever (1), as indicated in the following figure. If interventions have been carried out on the throttle bodies, the transmission of the accelerator control must be analysed not only at the accelerator handgrip but also near to the throttle bodies.

  • Page 68: Locks

    Maintenance LOCKS Check ¨ At the pre-delivery, at the first 1000 kilometers and then every 6000 kilo- meters Ignition/steering block switch This switch has four operating positions. Do not attach key rings or other objects to the ignition key that could obstruct the rotation of the steering.
  • Page 69 Maintenance Fuel cap lock Lift up the anti-dust cover. Insert the key, rotating it in a clockwise direction and lift up the cap. After refuelling, press the cap down and rotating the key contemporaneously to facilitate the closure. Press and hold the cap, let the key go free, bring it into a lon- gitudinal position and pull it out.

  • Page 70: Steering

    (see chapter F “Suspension and wheels”): BRUTALE 990 R - 1090 RR: 200 mm The clearance “h” between the axis of symmetry of the chain and the chain cover should be equal to the follow- ing values as shown in the figure.
  • Page 71 Maintenance Adjust¨ At the first 1000 kilometers and then every 6000 kilometers To adjust the chain tension, proceed as follows: Slightly loosen the 2 screws of the back wheel hub until they can freely turn. Using the special spanner as indicated in the figure, rotate the eccentric counterclockwise to tension the chain, or clockwise to loosen the chain, until the cor- rect play is reached (as described previously).
  • Page 72 Maintenance Chain lubrication Lubricate¨ At the first 1000 kilometers and at 6000 kilometers and then at every 12000 kilometers Clean the chain with a clean cloth and/or a jet of air. The chain is the type with sealing rings (O- RING);...

  • Page 73: Tyres

    Therefore maintain the correct tyre pressures to obtain better roadholding and the maximum wear from the tyres. The cold tyre pressures are indicated in the table. Description BRUTALE 990 R BRUTALE 1090 RR Brand and type PIRELLI - Diablo Corsa III PIRELLI - Dragon Supercorsa Pro...

  • Page 74: Wheels

    Maintenance WHEELS Visual check ¨ At the first 1000 kilometers and then every 6000 kilometers (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 75: Rear Wheel Hub

    Verify the length in the seat of the back damper spring, check the absence of leakages or oil blow-by and the adjusting functionality. Spring adjustment standard “A”: - Brutale 990 R: A = 161 mm - Brutale 1090 RR: A = 160 mm The shock absorber contains gas under high pressure.

  • Page 76: Side Stand

    Maintenance Compression and extension adjustment (rear suspen- sion): CLICK! (See the Adjustments Table - Chapter “F – SUSPEN- CLICK! CLICK! CLICK! CLICK! SION AND WHEELS” - page 38). CLICK! N.B. This operation can be made with the shock absorber in position on the motorcycle. For further checks on the round joints where the rear shock absorber is attached, it is necessary to carry out the phases of...

  • Page 77: Front Fork

    Maintenance FRONT FORK Substitute oil ¨ every 24000 kilometers The front fork is vitally important for the rideability and roadholding of the motorcycle. It is therefore necessary to substitute the fork oil at the prescribed intervals. Specified oil: SAE 7,5 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 78: Electrical System

    Maintenance ELECTRICAL SYSTEM Check the functioning ¨ At the pre-delivery, at the first 1000 kilometers and then every 6000 kilometers Carry out a detailed check on the various parts of the electrical system, the contacts between components and their good functioning. Consult chapter E “Electrical system”...
  • Page 79 Maintenance Turn the screw of the positive terminal and tighten it at the prescribed torque by using a torque wrench. Torque wrench setting: 7 ÷ 8 Nm 7 ÷ 8 N•m When the leads are mounted, replace the protection cover on the positive pole (see the figure). Mount the two negative terminal (-) leads on the rela- tive pole of the battery following the placement shown in the figure.
  • Page 80 Maintenance Turn the screw of the negative terminals and tighten them complying with the prescribed torque by using a torque wrench. Torque wrench setting: 7 ÷ 8 N•m Before tightening, verify that the cables are correctly oriented. 7÷8 N•m At the end of assembly, ensure that the cable of the positive terminal is placed inside the structure of the back sub-frame (see the figure).

  • Page 81: Instruments And Warning Lights

    Maintenance INSTRUMENTS AND WARNING LIGHTS Warning lights Check ¨ Multifunction display At the pre-delivery, at the first 1000 kilometers and then every 6000 kilo- “SET” button meters 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 correct- Tachometer ly, consult chapter E “Electrical system”...
  • Page 82 If it needs to be filled up, contact a MV Agusta licensed service center. If the war- ning light turns on even if the level is ade- quate, stop driving and contact a MV Agusta licensed service center. (*): This function is present only on certain models...
  • Page 83 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) “CHRONO” (Chronometer) “SERVICE” (Expiration of scheduled maintenance service) “TC” (Traction control) “IMMOBILIZER”...
  • Page 84 Maintenance “RUN” mode In addition to the speedometer, the display shows the following functions (see §4.4.2.): • Total odometer “TOTAL” • Trip counter 1 “TRIP 1” • Trip counter 2 “TRIP 2” “CHRONO” Mode This mode turns on the Chronometer and saves the recorded information (see §4.4.4.).
  • Page 85 Maintenance “TC” Mode This Mode adjusts the engine traction control level to your driving requirements (see §4.4.6.). J “IMMOBILIZER” Mode The “IMMOBILIZER” lets the engine start only if it reco- gnises the original starter key. This is actually an anti-theft device built into the electronic circuit of the vehicle, since only authorised people are allowed to drive it.
  • Page 86 Maintenance Trip reset To reset “TRIP 1” and “TRIP 2”, proceed as follows. The display modes may be changed or set when the engine is off, the gears are in neu- tral, the motorbike is stationary, and with your feet on the ground. Do not change the display while driving.
  • Page 87 Maintenance - Now, press “OK” for less than four seconds, it will clear the display. Otherwise, press “SET” for more than four seconds to stop the reset procedure. - Press “SET” for less than four seconds until “TRIP 2 RESET” appears. Press “OK”...
  • Page 88 Maintenance - Now, press “OK” for less than four seconds, it will clear the display. Otherwise, press “SET” for more than four seconds to stop the reset procedure. - Press “OK” again to quit “TRIP 2 RESET” and move on to the next mode. How to set the measurement units The following measurement units may be changed at the same time:...
  • Page 89 Maintenance - Press “OK” for over four seconds; the measurement unit of the speedometer starts blinking. - Press “OK” to change from Km/h to Mph, or vice versa. When you change the measurement unit of the speedometer, the following quantities will change accordingly: - Odometer (total, trip): Km –>...
  • Page 90 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 seconds and from the tenths of a second will start blinking.
  • Page 91 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. If the time taken to cover the last lap is lower than the time measured during the earlier laps, the new time is displayed on “BEST LAP”.
  • Page 92 Maintenance - Press “OK” to display the fastest lap time (“BEST LAP”) and the relevant lap number. - Then, press the headlights button repeatedly to display all the recorded times since the 1st lap, in a sequence. - Once all times have been displayed, press “SET” to quit “LAPS VIEW”...
  • Page 93 Maintenance - Press “SET” repeatedly for less than four seconds until “BEST LAP RESET” appears. - Press “OK” for over four seconds until “BEST LAP” starts blinking. - Now, press “OK” for less than four seconds to delete the value. Otherwise, press “SET” for over four seconds to stop the deletion procedure.
  • Page 94 Maintenance - Press “SET” for less than four seconds until “LAPS RESET” appears. - Press “OK” for over four seconds until “LAST LAP” starts blinking. - Now, press “OK” for less than four seconds; all the saved times are deleted. Otherwise, press “SET” for over four seconds to stop the deletion procedure.
  • Page 95 Maintenance - Press “OK” again to quit “LAPS RESET” and go back to Chronometer Mode. “SERVICE” Mode It shows the distance the motorbike will have to cover in order to undergo the next scheduled service. Once the maintenance operations have been perfor- med, it is possible to reset the mileage to the next scheduled service.
  • Page 96 Maintenance - Press “OK” for over four seconds; the value of the mileage will start flashing. - By pressing “OK” once more, the mileage is reset to the prescribed value of the distance to be covered in order to undergo the next scheduled service. “TC”...
  • Page 97 Maintenance - Press “OK” for less than four seconds: the traction control level rises up to the next value. Such value may range between 0 and 8. - Press “OK” for over four seconds to confirm the selec ted traction control level. “IMMOBILIZER”...
  • Page 98 Maintenance - Press “SET” for less than four seconds to set the first digit of the code. - Press “OK” for less than four seconds to set the first digit between 0 and 9. - Once the digit has been selected, press “OK” for over four seconds to confirm the first digit of the code.
  • Page 99 MV Code Card. If the problem persists, contact a MV Agusta licensed service centre. How to select the mapping of the control unit *...
  • Page 100 Maintenance - Press “OK” button to access to “RUN” mode. WARNING If a fault is detected on the vehicle when the engine is off, do not start engine. Fault during vehicle riding - If a fault is detected during riding, the lower portion of the display shows the warning alert shown in the pic- ture.

  • Page 101: Lights

    Maintenance LIGHTS Check ¨ At the pre-delivery, at the first 1000 kilometers and then every 6000 kilo- meters If any of the warning lights or the main lights are burnt out, replace them as follows. Replacing the low beam bulb - Remove the headlight lateral fixing screws (1).
  • Page 102 Maintenance - Remove the headlight rear screw. - Remove the front part of the headlight from its sup- porting shell. - Remove the protective headlight cover. - Detach the low beam bulb connector. - Release the retaining spring. - Extract the burnt-out low beam bulb. Do not touch the bulb glass with bare hands.
  • Page 103 Maintenance Replacing the high beam bulb - Remove the headlight from its support as described for the hgh beam. - To take the headlight lamp out, press the connector on the side and pull it outwards. - Detach the connector from the burnt-out bulb. Do not touch the bulb glass with bare hands.
  • Page 104 Maintenance - Pull out the license plate light bulb holder. - Extract the burnt-out bulb. - Fit the new bulb. - Replace the bulb holder. - Push back the cable rail in touch with the upper sur- face. - Replace the cable rail fixing screws. Replacing the fuses - The recharge fuse is located under the driver’s sadd- le, in the position shown in the figure.
  • Page 105 Maintenance - Unfasten and lift the lid of the fuse box. Turn the ignition switch on “OFF” before checking or replacing the fuses in order to avoid accidental short circuits with conse- quent risk to damage other electric compo- nents. - To identify the position and function of the fuses, refer to the information shown on the adhesive label and in the enclosed electrical diagram.

  • Page 106: Front Headlamp

    Maintenance FRONT HEADLAMP Check adjustment – At every variation of the motorcy- cle set-up Each time a variation to the set-up of the motorcycle is carried out, it is good practice to carry out the adjust- ment of the headlamp beam. The adjustment of the front headlight can be per- formed operating the screw shown in the side figure.
  • Page 107 Maintenance Front headlight adjustment Place the motorcycle at 10 meters from a vertical wall. Ensure that the ground is even and that the optical axis of the projector unit is perpendicular to the wall. The motorcycle must be in a vertical position. Measure the height of the center of the beam from the ground and mark it with a cross on the wall using a piece of chalk.
  • Page 108 Maintenance - 92 -...
  • Page 109 Bodywork SECTION Revision 1 - 1 -...
  • Page 110 Bodywork SUMMARY FAIRING ASSEMBLY ..........................Page 3 FRONT HEADLAMP DISASSEMBLING ....................Page 4 INSTRUMENTATION PANEL DISASSEMBLING ................Page 5 HANDLEBAR DISASSEMBLING ......................Page 6 HEADLIGHT SUPPORT DISASSEMBLING ..................Page 7 FUEL TANK..............................Page 8 FUEL TANK SIDE PANEL REMOVAL ....................Page 9 FUEL TANK REMOVAL.........................Page 10 AIR FILTER COMPARTMENT........................Page 15 AIR FILTER COMPARTMENT REMOVAL ....................Page 16 AIRBOX REMOVAL ..........................Page 16 TAIL UNIT..............................Page 20...

  • Page 111: Fairing Assembly

    Bodywork FAIRING ASSEMBLY - 3 -...

  • Page 112: Front Headlamp Disassembling

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

  • Page 113: Instrumentation Panel Disassembling

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

  • Page 114: Handlebar Disassembling

    Bodywork HANDLEBAR DISASSEMBLING Before performing this operation, you should prelimi- narily carry out the disassembling of the front headlight and the instrumentation panel as described in the pre- vious pages. Disconnect the warning horn. Disconnect the main connectors. Disconnect the connectors of the turn indicators. - 6 -...

  • Page 115: Headlight Support Disassembling

    Bodywork If removal of the headlamp suport is required, unhook the headlamp support cables. Unscrew the two fixing screws of the handlebar U bolt. Rotate the U bolt and remove the handlebar. During the reassembly, you should pay attention to the right positioning of the U bolt in regard to the handlebar.

  • Page 116: Fuel Tank

    Bodywork FUEL TANK - 8 -...

  • Page 117: Fuel Tank Side Panel Removal

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

  • Page 118: Fuel Tank Removal

    Bodywork Release definitely the side panel by moving it towards the rear part in order to release it from the special rub- bered screw (1) fastened to the fuel tank. Make the same operations in order to remove the right side panel.
  • Page 119 Bodywork Operate on the right side. Unscrew and remove the special rubbered screw (1) on the tank support. Unscrew and remove the two support fixing screws (1) of the tank support. Make the same operations on the left side of the motorcycle in order to remove the tank support.
  • Page 120 Bodywork Remove the rear screw (1). Lift and lean the fuel tank on a side in order to easily work on the rapid unions on the fuel pump flange. In order to make the unions disengagement N.B. operation from the fuel pump flange easier it’s recommended the presence of two ope- rators, one that works on the tank support and the other on the rapid unions release.
  • Page 121 Bodywork Disconnect the connector of the fuel flange pump (1) of the main wiring. Withdraw the fuel breather pipe (1) connected to the three-way union. Removing of the fuel tank plug Insert the motorcycle key in the fuel plug lock, rotate clockwise and open the plug.
  • Page 122 Bodywork Unscrew and remove the four screws (1) . During the reassembly of the fuel tank plug make the same operations in the opposite direction in regard to disassembling ones by tightening them at the descri- bed torque and apply the indicated brakethread. Fuel filler cap fixing screws torque pressure: - External screws 4 ÷...

  • Page 123: Air Filter Compartment

    Bodywork AIR FILTER COMPARTMENT - 15 -...

  • Page 124: Air Filter Compartment Removal

    Bodywork AIR FILTER COMPARTMENT REMOVAL Before removing the air filter compartment you should primarily remove the fuel tank as described in the para- graph “Tank” of this chapter. Disconnect the temperature and air pressure sensor connector (1). AIRBOX REMOVAL Release the fixing springs (1) of the air filter compart- ment box to the throttle body.
  • Page 125 Bodywork Unscrew and remove the two side fixing screws (1) of the air filter compartment to the frame. Disconnect the breather piping (1) from the block. Lift the airbox. - 17 -...
  • Page 126 Bodywork Loosen the clamp (1). Disconnect the secondary air hose from the hose air- box. Remove the air filter compartment from the throttle body. - 18 -...
  • Page 127 Bodywork During the reassembling make the same operations of the disassembling. If you had to remove the fixing screws of the throttle body springs (1), during their reassembling apply the described brakethread and tighten them to the indica- ted torque. Torque wrench of the fixing screws of the throttle body fly springs: 5 ÷...

  • Page 128: Tail Unit

    Bodywork TAIL UNIT - 20 -...

  • Page 129: Tail Unit Removal

    Bodywork TAIL UNIT REMOVAL PRELIMINARY OPERATION Fuel tank side panel removal Operate on the left side of the motorcycle. Release the trailing part of the left side panel by relea- sing the peg (A) from its seat (B) on the rubbered sup- port, fastened in the rear part of the tank, making it accomplish the movement shown in the figure.
  • Page 130 Bodywork Rider seat removal Insert the ignition lock key in the opening seat lock on the left side of the motorcycle and rotate it clockwise. In the meantime push lightly on the rider seat. The lock will be released. Lift and remove the rider seat. Passenger seat removal Rotate the fixing clip of the passenger seat.
  • Page 131 Bodywork Removing the tail side panels. Unscrew and remove the two upper screws fixing the tail side panels. Unscrew and remove the lower rear screw fixing the tail side panels. Unscrew and remove the lower front screw fixing the tail side panels. - 23 -...
  • Page 132 Bodywork Be careful to put aside the four nylon washers of the tail side panels on both sides when removing. Then remove the tail side panels. Tail unit removal Extract the tail light connector from its seat on the frame. - 24 -...
  • Page 133 Bodywork Release the connector. Remove the cable of the lock transmission from its housing plate, with the aid of a screwdriver. Take the cable of the lock transmission out of its hou- sing in the thumbstick. - 25 -...
  • Page 134 Bodywork Unscrew the four fixing screws (1) of the rear part tale unit. Take out towards the back and remove the tail. Unscrew and remove the two screws (1) and release the tail light. - 26 -...

  • Page 135: Under-Tail Assembly

    Bodywork UNDER-TAIL ASSEMBLY - 27 -...
  • Page 136 Bodywork UNDER TAIL UNIT REMOVAL Remove the passenger and rider seats, the side panels and the rear tail piece as described in the pre- vious paragraph “Tail unit removal”. Remove the clamp. Disconnect the connection of the direction indicator (2 connections) and of the number plate light (1 connec- tion).
  • Page 137 Bodywork Remove completely the number plate holder. Unscrew the fixing screws of the battery connections. Disconnect the negative pole first. Remove the battery from its seat. - 29 -...
  • Page 138 Bodywork Remove the fixing screw of the solenoid starter. Unscrew the four fixing screws of the under tail unit. Remove the under tail unit. - 30 -...
  • Page 139 Air intake injection system SECTION Revision 0 - 1 -...
  • Page 140 IN ECTION TIME IN ECTION VOLUME ....................Page 3 IN ECTION TIME COMPENSATION......................Page 4 IN ECTION ARREST CONTROL ......................Page 4 IGNITION SYSTEM............................Page 5 POSITIONS OF ENGINE-CONTROL SYSTEM PARTS BRUTALE 990 R - 1090 RR .........Page 6 FUEL PUMP CONTROL SYSTEM ......................Page COMPONENTS ............................Page 9 SENSORS ..............................Page 11 ENGINE PIC -UP ............................Page 14...

  • Page 141: In Ection-Ignition System

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

  • Page 142: In Ection Arrest Control

    Air intake injection system The various sensors allow the injection time (volume) compensations to be carried out on the basis of the following signals. IGNITION SYSTEM SIGNAL DESCRIPTION ATMOSPHERIC PRESSURE SENSOR SIGNAL When the atmospheric pressure is low, the sensor sends a signal to the ECU to reduce the injection time (volume of the fuel injected) to compensate the lower presence of oxygen in the atmosphere.
  • Page 143 Air intake injection system DESCRIPTION This system belongs to the category of integrated systems of electronic digital ignition with static distribution and electronic petrol injection with a logic of the intermittent phased type (injection and cylinder ignition) This ignition system consists of an engine crankshaft position sensor (pick-up), a depression sensor beneath the throttle of cylinder 1, an ECU, four ignition coils of the top plug type and four spark plugs.
  • Page 144 Air intake injection system - 6 -...

  • Page 145: Fuel Pump Control System

    Air intake injection system FUEL PUMP CONTROL SYSTEM At the moment of KEYON, the system and the engine control unit are powered; once the condition of the relati- ve inputs have been checked, it activates the injection relay, feeding the petrol pump for a pre-set time, thus allowing the power circuit to be put under pressure.
  • Page 146 Air intake injection system Fuel feed system The fuel delivery system consists in the tank, the pump, the filter, delivery pipe (including fuel injectors) and pres- sure regulator. The fuel present in the tank is pumped into the delivery pipe at a pressure controlled by the rela- tive regulator and maintained at a certain constant value which is higher than the depression generated by the engine.

  • Page 147: Components

    Air intake injection system COMPONENTS Fuel pump The electric fuel pump that is situated inside the fuel tank consists of an electric motor, of the rotor, impeller, con- trol valve and pressure release valve. The ECU controls the ON/OFF condition as described in the section FUEL PUMP CONTROL SYSTEM. When electrical energy is supplied to the pump, the motor switches on and the impeller activates.
  • Page 148 Air intake injection system Fuel pressure regulator The fuel pressure regulator is a diaphragm pressure release valve that consists of a diaphragm, spring and valve. It always maintains the pressure of the fuel sent to the injector at 3.0 kg/cm2 (300 kPa). When the pressure of the fuel rises above 3.0 kg/cm2 (300 kPa) the excess fuel opens the valve of the regulator and therefore can return to the fuel tank.

  • Page 149: Sensors

    Air intake injection system SENSORS Atmospheric air temperature pressure The air intake sensor is situated on the right side of the air filter compartment and indicates both the atmo- spheric pressure and the air temperature. Intake air pressure sensor The sensor reveals the pressure of the intake air and this pressure is therefore converted into voltage that is sent to the ECU.
  • Page 150 Air intake injection system Intake air temperature sensor The temperature of the intake air is found measuring the resistance of the Thermistor. The resistance value read is proportionate to the voltage read by the ECU. The volume of fuel injected increases when the intake air temperature is low. The resistance of the Thermistor increases when the air temperature is low and diminishes when the temperatu- re is high (NTC type sensor).
  • Page 151 Air intake injection system Throttle body position The sensor of the throttle position is located in the cen- tre of the throttle body. This sensor is a potentiometer with a resistance which varies according to the opening angle of the accelera- tor.

  • Page 152: Engine Pic -Up

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

  • Page 153: Actuators

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

  • Page 154: Diagnostics System

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

  • Page 155: In Ection System - Electrical Diagram

    Air intake injection system IN ECTION SYSTEM - ELECTRICAL DIAGRAM FUSE FUSE FUEL PUMP - COILS - INJECTORS RELAYS MAIN RELAY FUSE - 17 -...
  • Page 156 Air intake injection system Connector MV Agusta Brutale Engine control unit pinout Vehicle Pin n Engine Pin n Input switch control panel key 12/29 Input r.p.m. sensor (+) Input r.p.m. sensor (-) Input engine phase sensor Input vehicle speed Input throttle potentiometer signal...
  • Page 157 Electrical system SECTION Revision 1 - 1 -...
  • Page 158 SUMMARY CONNECTORS ............................Page 3 COUPLINGS ..............................Page 3 FUSES................................Page 3 SEMICONDUCTOR PARTS........................Page 4 ELECTRICAL DIAGRAM BRUTALE 990 R - 1090 RR ................Page 5 PARTS LIST .............................Page 6 BATTERY ..............................Page 7 INITIAL BATTERY CHARGE ........................Page 7 BATTERY ASSEMBLY..........................Page 7 CHARGING SYSTEM..........................Page 10 BATTERY EFFICIENCY CHECK .......................Page 12...

  • Page 159: Connectors

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

  • Page 160: Semiconductor Parts

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

  • Page 161: Electrical Diagram Brutale 990 R - 1090 Rr

    Electrical system ELECTRICAL DIAGRAM BRUTALE 990 R - 1090 RR P/Y125 B/Y109 R/W 42 Gy/B137 Bk100 Y/G43 Lb64 Br 148 R/W 154 B 153 Lb62 Bk/R59 Bk/R61 R 152 Lb63 Y/Bk39 B 67-68 Bk/R60 92-93 G/B21 G/W 17 R/W 16...

  • Page 162: Parts List

    Electrical system PARTS LIST Parts list Parts list Parts list Ref. Description Ref. Description Ref. Description Frame/CPU earth Butterfly potentiometer Battery recharge Number plate light Water temperature sensor – CPU Clutch switch Right indicator Oil switch Starter motor Left indicator Electric fan Frame earth Diagnostic connector...

  • Page 163: Battery

    Electrical system BATTERY The battery mounted on this motorcycle is a sealed battery therefore no maintenance is required. The batteries recommended are the following: - KOYO KTZ10S (pre-activated). INITIAL BATTERY CHARGE Proceed with charging following the method on the packet that the battery came in or as indicated in the following table.
  • Page 164 Electrical system Insert the battery into the appropriate compartment. The initial battery charge should be carried out before mounting it on the motorcycle. Battery terminal assembly Assemble the positive (+) terminal lead on the relative battery pole, respecting the position shown in the figure. Rotate the screw of positive terminal lead and tighten to the prescribed torque using a torque wrench.
  • Page 165 Electrical system When the terminals are mounted replace the protec- tion cover on the positive pole (see figure). Connect the two negative (-) terminal leads to the rela- tive pole of the battery respecting the placing shown in the figure. Rotate the screw of negative terminal leads and tighten to the prescribed torque, using a torque wrench.

  • Page 166: Charging System

    Electrical system After the assembly operation, make sure that the positive terminal cable is positio- ned correctly inside the rear frame unit (see figure). PLACEMENT AND ASSEMBLY OF TERMINALS (WIRE TERMINALS) ON THE BATTERY POSITIVE WIRE (+) PROTECTION COVER NEGATIVE WIRE (-) POSITIVE POLE (+) NEGATIVE WIRE (-) NEGATIVE POLE (-)
  • Page 167 Electrical system A list of possible problems that could occur when the warning light is switched on. RESTORE OR CLEAN CON- WARNING LIGHT STILL ON PROBLEMS OCCUR NECTION WITH CONNECTION POSITIVE ON BATTERY RESTORE OR CLEAN CON- WARNING LIGHT STILL ON PROBLEMS OCCUR WITH CONNECTION NECTION...

  • Page 168: Battery Efficiency Check

    Electrical system BATTERY EFFICIENCY CHECK Battery current loss check • Remove the tail unit as described in chapter C “Bodywork”. • Turn the ignition switch to the “OFF” position. • Disconnect the cable from the positive (+) pole of the battery.
  • Page 169 Electrical system Charge feed check • Remove the tail unit • Switch on the engine and run it at 2000 r.p.m. with the light switch in the “ON” position and the selector on main beam Hl. Measure the voltage between the positive (+) and negative (-) terminals of the battery with a multi-tester.

  • Page 170: Starter System

    Electrical system STARTER SYSTEM The diagram below represents the starter system. - 14 -...
  • Page 171 Electrical system FUSE FUSE FUEL PUMP - COILS - INJECTORS RELAYS MAIN RELAY FUSE - 15 -...
  • Page 172 Electrical system FUSE FUSE FUEL PUMP - COILS - INJECTORS RELAYS MAIN RELAY FUSE - 16 -...
  • Page 173 Electrical system FUSE FUSE FUEL PUMP - COILS - INJECTORS RELAYS MAIN RELAY FUSE - 17 -...
  • Page 174 Electrical system FUSE FUSE FUEL PUMP - COILS - INJECTORS RELAYS MAIN RELAY FUSE - 18 -...
  • Page 175 Electrical system FUSE FUSE FUEL PUMP - COILS - INJECTORS RELAYS MAIN RELAY FUSE - 19 -...
  • Page 176 Electrical system FUSE FUSE FUEL PUMP - COILS - INJECTORS RELAYS MAIN RELAY FUSE - 20 -...
  • Page 177 Electrical system FUSE FUSE FUEL PUMP - COILS - INJECTORS RELAYS MAIN RELAY FUSE - 21 -...
  • Page 178 Electrical system FUSE FUSE FUEL PUMP - COILS - INJECTORS RELAYS MAIN RELAY FUSE - 22 -...
  • Page 179 Electrical system FUSE FUSE FUEL PUMP - COILS - INJECTORS RELAYS MAIN RELAY FUSE - 23 -...

  • Page 180: Fuses

    Impianto elettrico Electrical system FUSES - The fuses are located beneath the passenger seat. In order to access the fuses, it is necessary to remove the rider seat and then unscrew the connection to the passenger seat and remove. Replace the burned fuse. To identify the position and the function of the fuses, consult the information written on the adhesive and in the electrical diagram.

  • Page 181: Starter Motor Check

    Electrical system STARTER MOTOR CHECK If a fault has been diagnosed in the starter motor, it is necessary to proceed as follows with the check: • Connect a tester between earth and the starter motor terminal. • Check that there is continuity between the positive pole and the engine earth.
  • Page 182 Electrical system Starter relay check Remove the rider seat, disconnect the battery. Unhook the connector from the starter relay. Unscrew the fixing screw of the relay. Disconnect the cables of the starter motor and the positive cable of the battery from the relay. - 26 -...
  • Page 183 Electrical system Apply 12 volts to the terminals (1) and (2) of the relay and check the continuity between terminals B-M. Do not apply the battery voltage to the starter relay for more than five seconds to avoid overheating and therefore damaging the winding. - Using a multi-tester, check that the winding is on open circuit or if a resistance is present.

  • Page 184: Gearchange Position Switch

    Electrical system GEARCHANGE POSITION SWITCH The connector of the gear position sensor is located on the left beneath the tank. Disconnect the connector of the gear position switch and check the resistance value, using a multitester, in the six gears as well as the idle position, as shown in the attached table.

  • Page 185: Spark Plugs

    Electrical system If it is necessary to substitute the switch proceed by unscrewing the two fixing screws. SPARK PLUGS To accede to the ignition spark plugs, it is necessary to remove the following components: • Passenger seat • Rider seat •...

  • Page 186: Run Off Safety Switch

    Electrical system Remove the spark plugs utilising the appropriate 16mm hexagonal spark plug spanner. Check the resistance between the electrode and the screw cap of the spark plug as shown in the figure. Permitted resistance: 4.5 ÷ 5.5 K Carry out the test on all the spark plugs. RUN OFF SAFETY SWITCH Remove the instrument panel cover unscrewing the two fixing screws on the sides.
  • Page 187 Electrical system Remove the relative connector to the right hand control group as indicated in the figure. Remove the plug part of the connector. With the switch in the “RUN” position, check the conti- nuity between pins (2) and (5). - 31 -...

  • Page 188: Instrumentation

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

  • Page 189: Oil Pressure Sensor

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

  • Page 190: Instrument Panel Water Sensor

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

  • Page 191: Rpm Indicator

    Electrical system - Otherwise, replace the power unit. - Check for continuity in the orange-yellow cable between the terminal of the remote switch and terminal 2 of the motor of the power unit connector. - If the presence of voltage and mass on both the terminals is confirmed and the remote switch does not come on, replace the remote switch.

  • Page 192: Speed Sensor

    Electrical system SPEED SENSOR If the speed of the motorcycle is not indicated on the instrument panel, proceed as follows: • Check the condition of the fuse 6. If the fuse in question is in good condition, proceed with the check of the speed sensor as follows: Keeping the sensor connected to the system and with the key in the ON position, using a tester, check that when the sensor is positioned in front of one of the nuts...

  • Page 193: Horn

    Electrical system If the relay is in good condition but is not energised aboard the vehicle, disconnect the connector on the temperature sensor. Make a bridge between the two contacts as shown in the figure. With the key in the ON position, after just a few seconds the fans should start rotating.

  • Page 194: Switches

    Electrical system SWITCHES Check the continuity of each switch with a tester. If there is any anomaly, substitute the respective switch unit with a new one. - 38 -...
  • Page 195 Suspension and wheels SECTION Revision 1 - 1 -...
  • Page 196 Suspension and wheels SUMMARY FRONT WHEEL ..............Page 3 FRONT WHEEL REMOVAL .

  • Page 197: Front Wheel

    Suspension and wheels FRONT WHEEL BRUTALE 990 R BRUTALE 1090 RR N·m 12 ÷ 14 60 ÷ 65 5 ÷ 7 42 ÷ 46 Torque Kg·m pressure ft·lb Operation escription BRUTALE 990 R BRUTALE 1090 RR FRONT WHEEL Material Aluminium alloy...

  • Page 198: Front Wheel Removal

    Suspension and wheels Before proceeding with the removal and overhaul of the components relative to the front suspension, it is advisable to remove beforehand the front mudguard as described in detail in chapter H “Brakes”. Place the motorcycle on the rear stand. Special tool: No.
  • Page 199 Suspension and wheels Loosen the two screws (1) on both front wheel/fork attachments. During this operation, it is necessary to sup- port the wheel. Loosen the two screws (2) on the fork foot on the left side of the vehicle. Leave the screws partly tightened to facilitate the removal and the subsequent refitting of the axle.
  • Page 200 Suspension and wheels Front wheel bearing check Execute the following preliminary operations : - Fit the axle on the front wheel. - Turn in and bring the threaded bushing (Cod. 80A0A3469) into contact with the wheel spindle, tigh- tening it by hand. With the wheel spindle still mounted to the wheel, rota- te the wheel to check that the bearings are not pitted and rotate with a smooth action.
  • Page 201 Suspension and wheels Introduce the extractor until the internal ring of the bea- ring is hooked up. Introduce the wheel spindle and screw and manually block them. 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.
  • Page 202 Suspension and wheels Reassembly – front wheel bearings Before proceeding with the reassembly, accurately clean the bearing seats in the wheel hub. Lubricate the outer race of both bearings with special grease. Mount a bearing onto the special tool. Recommended product: AGIP GREASE 30 Special tool No.
  • Page 203 Suspension and wheels 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 204: Front Wheel Assembly

    Suspension and wheels FRONT 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 74. If the bearings have been replaced, refit the bearings, the inner spacer and the brake discs on the wheel using the reverse procedure to the removal.
  • Page 205 Suspension and wheels Insert the brake lines in the clips (2) and (3) on the front mudguard. Remove the front stand and rest the front wheel on the ground. While pulling the front brake lever, push down on the front suspension two or three times to allow the right- hand fork rod to position itself properly.
  • Page 206 Suspension and wheels Keep the brake lever pulled back with a clamp as shown in the figure on the left. Tighten the front brake caliper fixing screws to the pre- scribed torque. Torque pressure: 42 ÷ 46 Nm After completing the fitting operations, disengage the front brake lever from the clamp.

  • Page 207: Front Fork

    Torque Kg·m pressure ft·lb Operation Description Brutale 990 R Brutale 1090 RR FRONT SUSPENSION Hydraulic telescopic forks with the stems positioned upside down, equipped with Type a system of external adjustment for extension, compression and spring preload Ø stems (mm)

  • Page 208: Front Fork Overhaul

    Suspension and wheels FRONT FORK OVERHAUL Remove the front wheel as described in the paragraph ”Front wheel removal” of this Chapter. Before continuing with the other operations, loosen the two screws (1) on the fork on the left side of the vehi- cle and remove the bushing (2).
  • Page 209 Suspension and wheels Slacken the fork cap (1). Completely unscrew the cap and lower the sleeve as shown in the figure. This operation must be carried out keeping the stem in a vertical position. Unscrew the cap. Using the key, adjust the spring pre- load adjuster while blocking the rotation of the nut pla- ced on the pump rod.
  • Page 210 Suspension and wheels Remove the spring-push spacer (1) and the relative spacer ring. Slide out the spring complete with the spacer. Remove the internal rod for the extension adjustment. - 16 -...
  • Page 211 Suspension and wheels Turn the stem upside down and completely pour out the oil into a suitable container. Recover the oil in an appropriate container. Do not dispose of the used oil in the envi- ronment. Unscrew the lower central screw that fixes the pump unit.
  • Page 212 Suspension and wheels Lower the anti-dust seal (1) taking care to not damage the seat on the sleeve. Remove the retaining ring (1) with a screwdriver, taking care to not scratch the stem. Extract the sleeve from the stem by repeated blows at the end.
  • Page 213 Suspension and wheels Fork assembly check Check that the sleeve does not have marks on the external part that could have repercussions inside the assembly. Ensure that the inside is completely smooth, without any scratches. If necessary, substitute with a new part. Check for marks or scratches on all surfaces of the stem and check the condition of the chroming.
  • Page 214 Suspension and wheels Visually check for scratches and marks on the pump rod and check that it slides smoothly inside the pump unit without chamfering. Substitute if necessary. Assemble the stem into the sleeve, placing the ferrules into their seats with the respective washers. Utilise the special tool.
  • Page 215 Press the pump rod up and down until a perfect fluidity of movement is obtained. Recommended oil: - BRUTALE 990 R - 1090 RR: SAE 7,5 Check that the oil level is at an “X” value from the upper edge of the sleeve, including the upper edge as well.
  • Page 216 Suspension and wheels Insert the key on the pump nut (1) slightly pressing down the spring. Place the spring-push spacer (1) and the relative washer. 20 N•m Reassemble the complete cap with a new O-ring. Tighten the cap to the prescribed torque pressure. Stem cap torque pressure: 20 N•m Insert and tighten the complete lid (1) on the fork sheath.
  • Page 217 Assemble the left stem in its seat. To position the stem correctly, refer to the diagram in the figure on the side. Pay attention to respect the “X” assembly dimension, which is reported below: - BRUTALE 990 R: X = 193 mm - BRUTALE 1090 RR: X = 193 mm Screw in and tighten the three screws (1) at the base of the steering.
  • Page 218 - Spring preload: Turn counterclockwise to end stroke. - Rebound damping / Compression dam- ping (Brutale 990 R): Turn clockwise to end stroke. Spring preload - Rebound damping / Compression dam- ping (Brutale 1090 RR): Turn clockwise to end stroke, then counterclockwise until you hear the first click.

  • Page 219: Steering Assembly

    Suspension and wheels STEERING ASSEMBLY N·m 120 ÷ 125 18 ÷ 20 In contact + 10° Torque pressu- Kg·m ft·lb Operation - 25 -...

  • Page 220: Steering Assembly Overhaul

    Suspension and wheels STEERING ASSEMBLY OVERHAUL To operate on the steering assembly, it is necessary to remove the fork stems as described in this chapter, in the paragraph “Front fork overhaul”. Then remove the components according to the following order: - front headlight;...
  • Page 221 Suspension and wheels Remove the screw ring previously slackened and remove the steering base complete with the pin. Remove the anti-dust seal, the internal bearing ring and the ball bearing ring. If it is necessary to replace the steering base comple- te with pin, you must remove the parts of the lower steering bearing according to the procedure described as follows.
  • Page 222 Suspension and wheels Rotate the extractor nut by using a 27 mm spanner key until the anti-dust seal detaches from the steering pin. Remove the complete tool (code no. 800097889) from the steering pin and recover the anti-dust seal. The parts removed will have to be reused in the fol- lowing assembly operations of the new steering base.
  • Page 223 Suspension and wheels Reassembly of the frame head steering sleeve Clean the parts accurately so that a visual check can be made of the tube and the seats. There should not be marks or lines in the bearing seats. If so, substitute the parts as necessary. Lightly grease the contact area of the frame head stee- ring sleeve (see figure) and the threaded part with Agip Grease 30.
  • Page 224 Suspension and wheels Screw ring assembly After having accurately cleaned the screw ring and the seat of the steering head on the frame, apply the pre- scribed grease both on the threading and on the coni- cal part of the screw ring, then screw it manually onto the relative seat.
  • Page 225 Suspension and wheels Place the steering base on the corresponding support plate (special tool). Special tool No. 800097888 By using a press, squeeze down the lower steering bearing components on the steering pin. Now it is possible to remove the bearing assembly tools and proceed with the assembling of the steering base on the bike.
  • Page 226 Suspension and wheels Steering head assembly Position the steering head in its seat. Reposition the fork stems as described previously in this chapter. Tighten the three screws of the steering head as described previously. Check the exact position of the fork N.B.

  • Page 227: Rear Suspension

    45 ÷ 50 Torque Kg·m pressure ft·lb Operation Description BRUTALE 990 R BRUTALE 1090 RR REAR SUSPENSION Type Progressive, single shock absorber with rebound Progressive, single shock absorber with adjustable damping and spring preload adjustment rebound and compression (high/low speed)
  • Page 228 Suspension and wheels Rear shock absorber disassembly Remove the fuel tank as described in chapter C “Bodywork”. Lift up the rear part of the motorcycle (utilising a lift and safety straps) high enough to take the load off the shock absorber. Move the electric cabling towards the upper part of the right-hand plate of the frame, as illustrated.
  • Page 229 Check that the lower and upper bolt holes do not have axial (A) and radial (B) play. Check the length of the rear shock absorber spring. Standard spring adjustment (A): - BRUTALE 990 R : A = 161 mm - BRUTALE 1090 RR : A = 160 mm Check the functioning of the adjusters.
  • Page 230 Suspension and wheels Rear suspension adjustment The following operations can be also car- N.B. ried out with the rear shock absorber assembled to the motorcycle. Rebound damper (rear suspension) The adjustment can be performed by operating on the screw placed on the lower side of the shock absorber, and it is obtained from the standard position.
  • Page 231 Suspension and wheels Type of set-up (only rider) BRUTALE 990 R On road On race track Rebound damping 16 clicks 10 clicks Type of set-up (with passenger) BRUTALE 990 R On road On race track Rebound damping 16 clicks Type of set-up (only rider)
  • Page 232 Suspension and wheels Check for eventual axial play of the bolt holes of the connecting rod (2). Substitute if worn. Rear shock absorber support plate removal Remove the three screws (1) indicated in the figure and remove the support plate (2). When reassembling, it is necessary to apply a special product to the three screws.
  • Page 233 Suspension and wheels Reassembly rocker arm assembly Reassemble the rocker arm assembly after having cleaned and greased the seat of the special screw situated on the swingarm. Screw in the screw without tightening it. Recommended grease : Agip Grease 30 Assembly rear shock absorber Accurately clean all parts.

  • Page 234: Rear Wheel Hub And Swingarm

    N·m 30÷35 20÷22 45÷50 200÷220 28÷32 220÷240 140 5÷7 70÷75 30÷35 18÷20 Torque Kg·m pressure ft·lb Operation Description BRUTALE 990 R BRUTALE 1090 RR REAR WHEEL Material Aluminium alloy Aluminium alloy Dimensions 6.00” x 17” 6.00” x 17” REAR TYRE...

  • Page 235: Rear Wheel Removal

    Suspension and wheels REAR WHEEL REMOVAL Before checking and overhauling the rear wheel hub assembly it is necessary to carry out the following pre- liminary operations: Place the motorcycle on the rear stand. Special tool N. 800092642 Remove the retaining ring (1) of the wheel nut. Remove the rear wheel by removing the polygonal nut, using the following tools: •...
  • Page 236 Suspension and wheels After having carried out the rear wheel removal, sup- port the motorcycle with a lift as shown in the figure. Remove the rear stand. Remove the safety ring (1) of the crown flange-fixing nut. Slacken the nut of the flange by rotating it in an anti- clockwise direction as shown in the figure.
  • Page 237 Suspension and wheels Slacken the fixing screws (1) of the wheel hub. Remove the screw complete with bushing. Extract the chain guard by pulling it out from the back part of the wheel (see figure) so that it is freed from its position on the swingarm.
  • Page 238 Suspension and wheels Remove the wheel spindle nut (2) previously slacke- ned and the spacer ring (4) underneath. Remove the rear sprocket unit (3) and the spacer ring (5) underneath. Remove the rubber clamp (1) around the rear brake pipe. - 44 -...
  • Page 239 Suspension and wheels Slacken the two screws (6) and remove the brake cali- per (7). 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. Brake caliper support flange removal Remove the Seeger retaining ring (1), the spacer ring (2), the flange (3) and the spacer ring underneath.
  • Page 240 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 bea- rings) or chamferings during rotation, substitute the wheel hub, complete with bearings with a new unit.

  • Page 241: Swingarm Removal And Overhaul

    Suspension and wheels SWINGARM REMOVAL AND OVERHAUL Before removing and overhauling the swingarm, it is necessary to execute the following preliminary opera- tions: - Remove the rear shock absorber and connecting rod as described in the paragraph “Disassembly rear shock absorber” and “rocker arm assembly removal” of this chapter.
  • Page 242 Suspension and wheels Unscrew the screw fixing the silencers to the support. Remove the upper silencer first, then the lower one. Remove the other components of the rear wheel assembly as shown in the operations previously described from page 41. Exhaust group removal Disconnect the lambda probe connector from the main cabling and pull outwards, on the right side of the vehicle.
  • Page 243 Suspension and wheels Unscrew the lower fixing screws of the oil radiator guard, positioned at the lower base of the water radiator. Remove the oil radiator guard. Remove the complete brake pump support. Loosen the nuts of the command cables of the exhau- st valve.
  • Page 244 Suspension and wheels Remove the screw of the plate which holds the com- mand cables of the exhaust valve in place. Extract the holding plate. Remove the terminals of the transmission cables of the exhaust valve. - 50 -...
  • Page 245 Suspension and wheels Remove the screw (2) connecting the oil radiator and the water radiator. Move the radiators slightly towards the front of the motorcycle, then remove the flange fixing the exhaust manifolds to the cylinder unit by unscrewing the nut (1). During this operation, take care not to touch the exhaust pipes in order to avoid burns.
  • Page 246 Suspension and wheels Remove the exhaust manifolds by turning slightly towards the right of the vehicle. Lower chain guide removal Remove the three screws of the chain guide. Remove the chain guide (1) complete with the two rear brake tube guide plates. - 52 -...

  • Page 247: Chain Removal

    Suspension and wheels CHAIN REMOVAL Cut the chain utilising the special tool. Special tool N. 8000B1439 Unscrew bolt (1) so that the tip is retracted into the hex nut. This tool coud be applied in any point of N.B. the lower section of the chain. Unscrew shoulder bolt (2) until you can insert the chain into the special tool.

  • Page 248: Chain Reassembling

    Suspension and wheels CHAIN REASSEMBLING Pick the new connecting link from the package. The connecting link is supplied lubricated with a special product that guarantees long life. Absolutely avoid wiping away the lubri- cant from the pin surfaces, as this would seriously reduce the connecting links opera- tional life.
  • Page 249 Suspension and wheels Closing the rivet link Closing the link utilising the special tool. Special tool N. 8000B1456 Put the assembling tool on the chain, placing the cen- tering pin between the chain rollers, in order to fit with the rivet link. Thread the bolt (1) with the fingers in until the outer plate is placed on the rivet link fork pins.
  • Page 250 Suspension and wheels Release the chain by retracting plate to open the posi- tioning rods and continue the operation cycle on the second pin to be riveted. Check for smooth flexing of the link and that the O- Rings are correctly positioned and not damaged or cut. When the riveting is over, check if the diameter of the head of both pins is between the following range: - Pin head diameter after riveting:...
  • Page 251 Suspension and wheels Swingarm pin removal Remove the screw (1) on the right side of the motorcy- cle. Remove the washer and push out the pin manually. Support the swingarm so that it does not drop to the ground. Now the swingarm can be extracted. Upper chain guide removal Remove the two screws (1) and the relative plates.
  • Page 252 Suspension and wheels Slide out in a forward position as shown in the figure. When reassembling, proceed in the reverse order of removal ensuring the correct positioning of the front reference peg. Bearings overhaul If it is necessary to substitute the bearings of the swin- garm because of excessive play, operate as follows: Remove the right and left spacer.
  • Page 253 Suspension and wheels Extract the spacer from the right side. Check the condition of both bearing seats and the seat of the spacer. If the spacer is in good condition, reinsert it onto the fork from the right side. Assembly of the roller bearings and the roller bea- ring units Pre-assemble the two roller bearing units on the left side and the two ball bearings on the right hand side...
  • Page 254 Suspension and wheels Wheel spindle unit check Check the condition of the wheel drive engagement splines. If it is worn, substitute as follows. After heating with a heat gun, remove the four fixing screws (1) of the brake disk flange sealed with Loctite 270.
  • Page 255 Suspension and wheels Utilising a press with an adequate punch for both the removal and assembly of the pins of the wheel drive engagement. When assembling, apply force on the crown of the peg not on the point. (see figure). Assemble the brake disc carrier plate by tightening the screws to the prescribed torque pressure and then apply Loctite 270.
  • Page 256 Suspension and wheels Check that the coupling bushes of the gear flange sup- port (1) and the driving flange (2) do not show any signs of excessive or uneven wear. If the bushes are excessively worn, replace the entire set of flanges. Remove the 5 nuts (3) to free the crown (1) from the crown flange (2).
  • Page 257 Suspension and wheels Check that the coupling bushes of the gear flange sup- port (1) and the driving flange (2) do not show any signs of excessive or uneven wear. 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 258 Suspension and wheels Grease the roller bearing. Introduce the first bush, the spacer and then the second bush. The grease used must have the following characteristics: – Lithium soap grease with a mineral oil base – Consistency NLGI: 2 – Dripping point: 181° C –...
  • Page 259 Suspension and wheels Reinsert the rubber clamp (1) around the rear brake pipe. Insert the spacer with neck illustrated in the figure onto the wheel pin. Insert the crown wheel assembly, the second spacer ring and the wheel pin fixing nut. Reassemble the chain as described at pages 54÷56 of this chapter.
  • Page 260 Suspension and wheels Reposition the nut of the flange (1) with the relative washer (2) without tightening. 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.
  • Page 261 Suspension and wheels Assemble the retaining ri ng (1). Reassemble the lower chain pad, the upper chain guard and the central exhaust manifolds respectively. - 67 -...
  • Page 262 Suspension and wheels Rear wheel assembly In the case of substitution of the rear tyre it will be necessary to effectuate the balancing of the wheel before assembling it. Follow the instructions described at page 74. Insert 1st gear. Reassemble the rear wheel. Tighten the wheel axis nut to the prescribed torque pressure.
  • Page 263 Suspension and wheels Straighten the metal tongue with a flat-head drift and hammer. Unscrew the pinion wheel retaining nut. Slacken the chain (see page 43), bring it forward and slide it off the pinion wheel. Effectuate this operation only if the pinion wheel has to be substituted.
  • Page 264 Suspension and wheels Reassemble the pinion wheel cover after having clea- ned the support base. 25 N•m Screw in the four screws lightly and proceed with the tightening, screwing down respectively on the three screws M8 (1) and on the screw M6 (2). Torque pressure (M8 Screws): 25 N•m Torque pressure (M6 Screws):...

  • Page 265: Motorcycle Set-Up Adjustement

    This operation must be carried out by two N.B. persons. Check that the dimension X 1 is equal to: BRUTALE 990 R: X 1 = 225 mm BRUTALE 1090 RR: X 1 = 222 mm If the dimension X 1 differs from the indicated value, slacken the counternuts (1) of the connecting rods of the rear suspension.
  • Page 266 Suspension and wheels Using a ring spanner, adjust the distance between the two connecting rods by operating the adjuster bar (2) until the required X 1 level is reached. Manually and firmly tighten the two fixing counternuts (1) of the connecting rods until you hit the adjuster bar. Press down on the seat so that the shock absorber is compressed and then let it go back into its resting posi- tion.
  • Page 267 Calculate the static slack according to this formula: 1 – The value of the static slack should be equal to: BRUTALE 990 R : = 25 mm BRUTALE 1090 RR : = 22 mm If the static slack value...

  • Page 268: Wheel Balance Check

    Suspension and wheels At the end of the spring adjustment operation, tighten the upper lock ring as shown in the figure. After having completed the adjustment of the motorcy- cle set-up, it is necessary to adjust the tension of the chain.
  • Page 269 Suspension and wheels Rear wheel balancing Before mounting the rear wheel on the appropriate tool, insert the balancing tool into the central hole of the wheel. Special tool N. 800092865 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.
  • Page 270 Suspension and wheels Place the dial gauge as shown in the figure, and check the flatness. Flatness must not exceed: 0.5 mm. 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.
  • Page 271 Frame SECTION Revision 1 - 1 -...
  • Page 272 Frame SUMMARY FRAME REMOVAL PRELIMINARY OPERATIONS .........Page 3 THROTTLE BODY REMOVAL .

  • Page 273: Frame Removal Preliminary Operations

    Frame FRAME REMOVAL PRELIMINARY OPERATIONS Place the motorcycle on the rear stand. Special tool: code No. 800092642 Remove the components in the following sequence: - Tank side panels; - Radiator protective covers; - Passenger and rider seat; - Fuel tank; - Air filter compartment;...
  • Page 274 Frame Remove the components in the following sequence: - Front mudguard; - Front brake calipers; - Front wheel; - Water radiator; the procedure for removing the components indicated are described in chapter F “Suspensions and wheels”, chapter H “Brakes” and chapter L “Cooling and lubri- cating system.
  • Page 275 Frame Operating on the right side, free the wiring from the bands fixing it to the frame. Protect the area around to the clutch control cylinder with a cloth or paper. Remove the union and discharge the clutch fluid from the system into an appropriate container.

  • Page 276: Throttle Body Removal

    Frame Remove the steering assembly and the relative com- ponents of the front suspension as described in chap- ter F “Suspensions and wheels”. THROTTLE BODY REMOVAL Slacken the nut (1) fixing the accelerator control wiring to the support plate of the throttle body. Remove the connector (2) of the phase sensor by undoing the screw (3).
  • Page 277 Frame Loosen the nut (1) which clamps the accelerator com- mand cables to the throttle body. Fleet the accelerator control wiring and extract the pawl (A) of the opening wiring. Carry out the same operation on the pawl of the clos- ing wiring.
  • Page 278 Frame Disconnect the connections relative to the injectors of each cylinder. Operating alternatively on both sides of the motorcycle remove the supports of the tubing for checking the suc- tion by unscrewing the screw (1) fixing the support to the frame. Remove the complete throttle body assembly.

  • Page 279: Coils Dismantling

    Frame COILS DISMANTLING Disconnect the coil connectors (1) from the control unit support. Unscrew and remove the coil backing plate fixing screws (2). Remove the coils from their housings. SECONDARY AIR SYSTEM DISMANTLING Disconnect the connector (1) from the secondary air unit.
  • Page 280 Frame Loosen the two CLIC R 96105 clamps of the secon- dary air hoses connections to the cylinders using spe- cial pliers. Disconnect the secondary air hoses Unscrew the screws (1) and remove the secondary air valve with the related hoses. Remove the two rubber bands so to free the wiring from the frame.
  • Page 281 Frame Disconnect the connector (1) from the exhaust valve actuator. Remove the screws (2) fixing the actuator to the frame. Lean the actuator on the engine in order not to hamper the following operations. - 11 -...
  • Page 282 Frame Disconnect the connector of the voltage regulator. Slide out the main wiring and fold it backwards on the rear sub-frame. Fix the main wiring to the sub-frame with an elastic band. - 12 -...

  • Page 283: Frame Disassembly

    Frame FRAME DISASSEMBLY Operating in the same way on both sides of the motorcycle unscrew and remove the front screw fixing the engine cylinder head to the frame and collect the eccentric washer. Operating on the right side unscrew and remove the rear nut fixing the engine assembly to the frame.
  • Page 284 Frame Remove the screws fixing the frame to the union plates from both sides. Remove the frame rotating the steering sleeve upwards. Frame check Accurately clean the conical seats of the steering head housing. - 14 -...
  • Page 285 Frame Check that there are no marks or signs on all surfaces. Check that the area shown in the figure is not deformed (as a consequence of accident damage). Check that there are no marks of evident breakages along the frame tubes. If damage is found, substitute the frame.

  • Page 286: Frame Control Reference Measurements

    Frame FRAME CONTROL REFERENCE MEASUREMENTS To carry out a detailed check of the frame, herewith below are the reference measurements that are of fun- damental importance for the correct condition of the frame. - 16 -...
  • Page 287 Frame Steering head housing check Check the diameter and eventual ovalisation of the steering head housing, 5 mm from the lip of the bevel- ling as shown in the figure. Measure the ovalisation in diverse points as shown in the figure. - 17 -...

  • Page 288: Frame Assembly To The Motorcycle

    For the stamping and the homologation labels of the new frame, contact the MV AGUSTA service centre. Thoroughly clean the matching surfaces of the frame- engine cylinder head and frame-union plates.
  • Page 289 With regards to the positioning of the cables, fasteners and various wiring consult the various tables shown in the Spare Parts Catalogue Brutale 990 R - 1090 RR (Code No. 8000B3254). Carry out the sequence of operations of assembly in reverse order to removal for the correct assembly of the frame to the motorcycle.
  • Page 290 Frame - 20 -...

  • Page 291: Rear Sub-Frame Removal

    Frame REAR SUB-FRAME REMOVAL After having carried out the removal of all the neces- sary components described in the previous paragraph, perform the following operations. Undo the screw on the negative pole of the battery, then remove the engine ground cable. Disconnect the solenoid starter connector.
  • Page 292 Frame Undo the screw (2) which fixes the silencers to the frame. Once the wiring has been freed and collected as shown in the figure, it is possible to remove the rear sub-frame. Unscrew and remove on both sides the two lower screws fixing the rear sub-frame to the union plates taking care to collect the nuts.

  • Page 293: Engine Removal Preliminary Operations

    Frame At this point it is possible to remove the complete sub- frame assembly from the motorcycle. Rear frame unit assembly Carry out the operation of reassembling the rear sub- frame on the motorcycle in the reverse order of removal, taking care to tighten the fixing screws to the prescribed torque pressure.
  • Page 294 Frame Operating on the left side of the motorcycle, unscrew and remove the two fixing screws of the side stand switch. Remove the side stand assembly by unscrewing the three fixing screws. Gearchange lever removal Unscrew the fixing screw (1) and slide out the gear change lever (2).

  • Page 295: Exhaust Silencers Removal

    Frame Remove the rear brake pump and related protection as described in chapter H “Brakes”. Disconnect the connector of the rear brake stop light from the main wiring. EXHAUST SILENCERS REMOVAL 24÷28 N•m Remove the rider footrests by unscrewing the two fix- ing (1) screws.
  • Page 296 Frame Remove the exhaust silencers retaining springs. Remove the screw fixing the silencers to the related support bracket. Slide out the silencers from the exhaust com- pensator. - 26 -...
  • Page 297 Frame EXHAUST GROUP REMOVAL The removal of the exhaust manifolds is NOTE not necessary in order to perform the engine disassembly. Carry out the fol- lowing operations only if it is necessary to check or replace the exhaust system. Disconnect the lambda probe connector from the main wiring and pull it outwards, on the right side of the vehi- cle.
  • Page 298 Frame Loosen the transmission cables adjusters of the exhaust valve. Remove the clamping screw of the plate which holds the transmission cables of the exhaust butterfly in place. Extract the holding plate. - 28 -...
  • Page 299 Frame Remove the ends of the transmission cables of the exhaust valve. Remove the screw (1) connecting the oil radiator and the water radiator. Move the radiators slightly towards the front of the motorcycle, then remove the flange fixing the exhaust manifolds to the cylinder unit by unscrewing the nut (2).
  • Page 300 Frame Unscrew the compensator fixing screws. Special tool: code 8000B2051 At the time of the assembly, apply the recommended thread locking adhesive to the threads of the screws and tighten them at the required torque. Recommended thread-locking fluid: Loctite 243 Torque pressure: 20 ÷...

  • Page 301: Engine Removal

    Frame ENGINE REMOVAL Remove the chain as described in chapter F “Suspensions and wheels”. Position an appropriate lift to support the rear suspen- sion/swingarm assembly as shown in the figure. Slacken the fixing screw of the swingarm pin by 1 turn. - 31 -...
  • Page 302 Frame Slacken the nut on the rear suspension rocker arm pin. Remove the lower engine support pin fixing nut. Operating on the left side extract the engine support pin. - 32 -...
  • Page 303 Frame Extract the bush shown in the figure from the union plates of the frame from both sides, by using the spe- cific tool. Special tool: No. 8000B4415 Remove the engine assembly from the union plates by dragging it forwards. Operating on the right side, remove the swingarm pin fixing screw (1) taking care to collect the washer (2).
  • Page 304 Frame Remove the right union plate. Remove the rear suspension pin fixing nut and slide out the pin from the left side. Remove the swingarm pin (1). Remove the left union plate. When reassembling proceed in the reverse order of removal, taking care to apply the prescribed grease and to tighten every fixing to the torque pressure indi- cated on page 19 of this chapter.
  • Page 305 Brakes SECTION Revision 1 - 1 -...
  • Page 306 FRONT BRAKE PADS SUBSTITUTION (BRUTALE 990 R) ....... . .Page...

  • Page 307: Front Brake System

    42 ÷ 46 (990 R) Torque 40 ÷ 42 (1090 RR) pressure Kg•m ft•lb Operation BRUTALE 990 R BRUTALE 1090 RR Description FRONT BRAKE Type Semi-floating double disc with the braking area in steel Semi-floating double disc with the braking area in steel Ø...

  • Page 308: Front Mudguard Removal

    Widen the attachment and slide it out of its seat. Remove the two right and left screws with their bushes from the mudguard. FRONT BRAKE PADS SUBSTITUTION (BRUTALE 990 R) Using pincers, position the pin in such a way as to faci- litate seeger removal. - 4 -...
  • Page 309 Brakes Remove the two seegers, one for each pin. Remove the two pins and remove the pad cover. NOTE: Re-assemble the pad cover with the stamp of the arrow turned upwards. Remove the two pads from the caliper. Repeat the same disassembling procedure for the other caliper.
  • Page 310 Brakes Every 6000 kilometres, check the wear of the pads. Front brake caliper The pad thickness must not be less than 1 mm. If the pads are excessively worn, substitute them. Disc Wear limit 1 mm For setting up front brake pads, carry out the opera- tions described above in reverse order.
  • Page 311 Brakes Loose the pads with a screwdriver. Push one of the two pads towards the central part of the caliper. Release the pad and remove it. - 7 -...
  • Page 312 Brakes Remove the second pad by carrying out the same ope- rations as described above. Every 6000 kilometres, check the wear of the pads. Front brake caliper The pad thickness must not be less than 1 mm. If the pads are excessively worn, substitute them. Disc Wear limit 1 mm Before setting up the pads, make sure the sheet-steel...
  • Page 313 Brakes Introduce the first pad by hooking it on the upper part, and inserting the lower part in the middle of the caliper. Make sure to hold the sheet-steel in its seat during the operation. Take the pad in touch with the pistons. - 9 -...

  • Page 314: Substitution And Bleeding Of The Front Brake Fluid

    Brakes Introduce the second pad by carrying out the same operations as described above. (In this case, it is not necessary to hold the sheet-steel pressed, since it is already held in its seat by the first pad). After inserting the newly supplied pad, assemble the front brake calipers on the motorbike and insert the relating fixing screws.
  • Page 315 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 pla- ced on the summit of the brake caliper). Put the other end of the rubber tube in a suitable con- tainer.
  • Page 316 Brakes Tighten the bleed screw, remove the rubber tube, care- fully clean the screw with alcohol, blow it dry and put 8 N•m the protective cap back on. Bleed screw tightening torque: - B4 990 R - 1090 RR: 8 Nm Slowly squeeze the brake lever to bring the pads in contact with the disc and also checking that there is no sponginess in the action of the lever.
  • Page 317 Brakes Top-up the level of the fluid until it reaches the maxi- mum mark. Carefully clean around the edge of the brake fluid chamber utilising a clean cloth. Imperfect cleaning of this component could cause the loss of small quantities of brake fluid whilst riding.

  • Page 318: Front Brake Calipers Substitution (Brutale 990 R - 1090 Rr)

    Place the cap on the brake fluid chamber and tighten the two lateral fixing screws. FRONT BRAKE CALIPERS SUBSTITUTION (BRUTALE 990 R - 1090 RR) • It is advisable to remove the brake pads to facilitate the operation (only for B4 990 R).

  • Page 319: Front Brake Pump Removal

    Brakes FRONT BRAKE PUMP REMOVAL Remove the cap from the front brake fluid reservoir and drain the reservoir with a syringe. 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.
  • Page 320 Brakes Remove the fixing screw that fixes the pump to the handlebar. Open the clamp. Push down to remove the pump from the reference pin. To substitute the front brake switch remove the screw shown in the figure. After having carried out the overhaul of the front brake pump assembly, carefully wash and bleed the front brake system as previou- sly described in this chapter.

  • Page 321: Front Brake Lever Removal

    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. 8÷10 N•m Grease the pin with the specified product. 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 322: Clutch Lever Removal

    Brakes CLUTCH LEVER REMOVAL Remove the nut shown in the figure. Unscrew the pin and extract it. Remove the clutch lever. When reassembling, be careful to insert the pin of the pump piston into the seat situated on the lever (see figure). Grease the pin with the specified product.

  • Page 323: Front Brake Discs

    Brakes For the reassembly of the lever tighten the pin. Keeping the pin still, tighten the nut with a screwdriver. Clutch lever nut torque pressure: 8 ÷ 10 N • m 8÷10 N•m FRONT BRAKE DISCS Check the thickness of the front discs utilising a micro- meter gauge.

  • Page 324: Front Brake Discs Removal

    Brakes FRONT BRAKE DISC REMOVAL Remove the front wheel from the motorcycle (see chapter F “Suspensions and wheels”). Place the wheel in a horizontal position on a work plane and remove the five screws of each disc procee- ding in a star-like mode for the removal. Visually check the discs for lines or score marks.
  • Page 325 Brakes Front disc assembly Thoroughly clean the contact surfaces of the discs and the wheel. Accurately grease all relative surfaces of the disc befo- re reassembling. Apply thread-locking fluid to the five fixing screws of the disc. Recommended thread-locking fluid: Loctite 243 Screw in the screws lightly, proceeding in a star-like mode.

  • Page 326: Rear Brake System

    16 ÷ 18 16 ÷ 18 18 ÷ 20 Torque Kg•m pressure ft•lb Operation Description BRUTALE 990 R BRUTALE 1090 RR REAR BRAKE Type Steel disc Ø disc (mm) Caliper (Ø piston mm) 4 pistons Ø 25,4 Disc thickness (mm)

  • Page 327: Rear Brake Pads Substitution

    Brakes REAR BRAKE PADS SUBSTITUTION Place the motorcycle on the rear stand. Special tool N. 800092642 Remove the exhaust protection. Remove the retaining ring (1) of the wheel nut. Remove the rear wheel by removing the polygonal nut, using the following tools: Torque wrench 55 mm polygonal spanner Utilising a torque wrench, slacken the rear wheel nut.
  • Page 328 Brakes Remove the rear wheel nut. 220÷240 N•m When reassembling, tighten the rear NOTE wheel nut to the prescribed torque pressu- Rear wheel nut torque pressure: 220 ÷ 240 N•m Grease only the threaded section. Take care not to apply grease to the tapered section of the nut.
  • Page 329 Brakes Remove the pad support pin and the relative spring. Remove the pad by letting it drop down. Rear brake pads Rear brake caliper Wear/substitution check: the first time after 1000 kilometres; then every 6000 kilometres. Check the wear condition and the thickness of the brake pads on the calipers.

  • Page 330: Substitution And Bleeding Of The Rear Brake Fluid

    Brakes Tighten the pin to the prescribed torque pressure. Rear brake caliper pin torque pressure: 15 ÷ 20 N•m 15÷20 N•m SUBSTITUTION AND BLEEDING OF THE REAR BRAKE FLUID The operation described herewith must be carried out with the engine cold: the position of the brake fluid tank could cause grave burns.
  • Page 331 Brakes Remove the rubber clamp fixing the rear brake fluid tube. Remove the fixing screws of the rear brake caliper. For reassembly, tighten the two screws to the prescri- bed torque pressure. Rear brake caliper screw torque pressure: 18 N•m Apply Loctite 243 18 N•m Remove the rear brake caliper from the motorcycle...
  • Page 332 Brakes Fill the rear brake fluid reservoir until the fluid reaches the maximum level. Recommended brake fluid: AGIP Brake Fluid DOT 4 Utilise exclusively the prescribed brake fluid. Use only new brake fluid from sealed containers. NEVER utilise old or used brake fluid.

  • Page 333: Rear Brake Caliper Substitution

    Brakes REAR BRAKE CALIPER SUBSTITUTION To facilitate the operation, remove the brake pads as described previously. Remove the crown wheel as described in chapter F “SUSPENSIONS AND WHEELS”. Empty the system of brake fluid as described in para- graph “Substitution and bleeding of the rear brake fluid”.
  • Page 334 Brakes Rear brake pump removal Carry out the emptying of the brake system as pre- viously described in paragraph “Substitution and blee- ding of the rear brake fluid”. Remove the clips complete with the fixing pin of the rear brake lever and the pump control fork by rotating and successively pushing inward as shown in the figu- Unscrew the union indicated by the arrow in the figure, thereby freeing the pump the brake tubing.

  • Page 335: Rear Brake Disc

    Brakes After having carried out a check on all components and substituted those used, damaged or defective proceed 16÷18 N•m 8÷10 N•m with the assembly by following the procedure in rever- se order of removal. Substitute the gaskets of the pump/caliper NOTE hoses.
  • Page 336 Brakes Check the rear brake disk level using a comparator and resting the disk on a levelling table. Use the same procedure for the front brake disks. The planarity value must not exceed 0.3 mm. Utilise a micrometer gauge with support to carry out this check.
  • Page 337 Cooling system and lubrication system SECTION Revision 0 - 1 -...
  • Page 338 Cooling system and lubrication system SUMMARY COMPLETE COOLING SYSTEM ASSEMBLY AND LUBRICATION SYSTEM...........Pag.3 COOLING SYSTEM LEA AGE CHEC ....................Pag.4 EXPANSION TAN CAP CHEC ......................Pag.4 ENGINE COOLANT EXTRACTION......................Pag.5 EXPANSION TAN REMOVAL .........................Pag.5 DISASSEMBLING WATER RADIATOR ....................Pag.8 COOLING FAN DISMANTLING .......................Pag.12 CHEC ING COOLING FAN STARTER.....................Pag.14 COOLING FAN REASSEMBLY ........................Pag.14 REMOVING THERMOSTAT VALVE ......................Pag.1 REASSEMBLING THERMOSTAT VALVE....................Pag.19...

  • Page 339: Complete Cooling System Assembly And Lubrication System

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

  • Page 340: Cooling System Lea Age Chec

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

  • Page 341: Engine Coolant Extraction

    Cooling system and lubrication system ENGINE COOLANT EXTRACTION Remove the ignition commutator cover unscrewing the two fixing screws (1). Open the cap of the expansion tank (2). Empty the cooling system of the coolant as follows: • Place under the engine a container to collect the discharged coolant;...
  • Page 342 Cooling system and lubrication system Disconnect the connector 1 of the ignition switch and place the switch on the frame, without removing it. On the right side of the motorcycle remove the clamp (1) connecting water radiator breather pipe to the expansion tank using specific pliers CLIC R 205.
  • Page 343 Cooling system and lubrication system In order to extract the pipe you should release it from the fixing point shown by the arrow in the figure on the side. Remove the ignition switch support unscrewing the four screws (1). On the left side of the motorcycle remove the clamp (1) connecting the water radiator charging pipe to the expansion tank using a specific pliers CLIC R 205 and its rubber clamp placed near the fluid supply tank.

  • Page 344: Disassembling Water Radiator

    Cooling system and lubrication system DISASSEMBLING WATER RADIATOR Remove the side protections (1) of the water radiator unscrewing the respective fixing screws on both sides of the radiator. Remove the oil radiator protective guard unscrewing the two fixing screws. Remove the upper plastic protection (1) unscrewing the two fixing screws.
  • Page 345 Cooling system and lubrication system Remove the protective grid (1) taking it out from its seat. Disconnect the connector (1) of the water radiator elec- tric fan on the right side of the motorcycle. Remove the clamp (1) on the water suction pipe cou- pling from the pump to the radiator using the specific pliers CLIC R 205.
  • Page 346 Cooling system and lubrication system Remove the clamp (1) on the water inlet pipe coupling to the radiator from the thermostat valve using the spe- cific pliers CLIC R 205. Specific tool - pliers CLIC R 205 Disconnect the fixing link rod on the right side of the water radiator.
  • Page 347 Cooling system and lubrication system Move the radiator towards the front side of the motorcycle in order to the release the water suction pipe coupling (1) from the pump to the radiator. Remove the radiator fixing screws (1) on the left side of the motorcycle.

  • Page 348: Cooling Fan Dismantling

    Cooling system and lubrication system Remove the radiator moving it right in order to release it from the peg (A) on the frame support. COOLING FAN DISMANTLING Remove the rubber clamp and free the cabling from the right and left sides of the fan units. Unhook the right fan unit cable connector from the spe- cial plate on the right fan support.
  • Page 349 Cooling system and lubrication system Unscrew the three screws and remove both the fan unit and support. Remove the clamp connecting the cooling fan to the support. Before replacing the fan it is important to remove the three blocking nuts (1) from the fan (2) and the guard (3) attached to the support (4).

  • Page 350: Chec Ing Cooling Fan Starter

    Cooling system and lubrication system CHEC ING COOLING FAN STARTER In order to verify the efficiency of the electric fan starter, Fan motor Ampmeter Motorino this starter must be connected as shown in the figure by elettroventola Amperometro using voltmeter and amperometer. During the test the starter must be powered.
  • Page 351 Cooling system and lubrication system Measure the minimum span between the fan and radiator pack using a feeler gauge as illustrated in the diagram. Perform the measurement several times in the mini- mum span area around the entire fan. The minimum distance “d” must be in the following dimensional range: 1.5 4.5 mm.
  • Page 352 Cooling system and lubrication system Fit the left fan unit cabling to the related support using a pull clamp. Fit the right fan unit cable connector to the special plate on the right fan support. Position the right fan unit cabling as shown in the dia- gram and fit to the related support using a pull clamp.

  • Page 353: Removing Thermostat Valve

    Cooling system and lubrication system Fit the right and left fan unit cabling using rubber clamps. REMOVING THERMOSTAT VALVE Remove the fixing screws (1) of the thermostat valve cover. Remove the cover of the thermostat (1). Remove the inside thermostat (2). - 17 -...
  • Page 354 Cooling system and lubrication system Checking thermostat valve Check to see if the thermostat pad is damaged. Check the functioning of the thermostat as follows: • Suspend the thermostat by a piece of string threa- ded through the flange as indicated in the figure. •...

  • Page 355: Reassembling Thermostat Valve

    Cooling system and lubrication system REASSEMBLING THERMOSTAT VALVE Insert the O-ring (1 in its appropriate seat on the cover of the thermostat. Check the condition of the O-ring previously utilised. If the O-ring is not in good condition substi- tute it ith a ne one.
  • Page 356 Cooling system and lubrication system Insert the cover of the thermostat, complete with ther- mostat onto the engine. 10 N m Tighten the three fixing screws (1) to the prescribed torque pressure. Torque pressure 10 N m If the water temperature sensor connector was remo- ved previously, the following action must be taken.
  • Page 357 Cooling system and lubrication system Block the water temperature sensor electrical cable with an elastic clamp as illustrated in the diagram. REASSEMBLING E PANSION TANK Position the tube in respect of the expansion tank as indicated in the figure. Position the expansion tank on the frame; if the opera- tion is difficult, slightly turn the tank clockwise.
  • Page 358 Cooling system and lubrication system Insert the radiator water breather pipe (1) and the over- flow pipe (2) inside the seats on the plastic clip (3). 10 12 N m Reassemble and fix the ignition switch fixing support (4) using the four screws (5). Scre tightening torque 5 10 12 N m...
  • Page 359 Cooling system and lubrication system Assemble the ignition switch (1) and the tank ancho- ring rod (2) and fix into place with the two screws (3). Screw tightening tor ue (3): 8 ÷ 10 N•m Thread-locking fluid used: Loctite 43 8÷10 N•m On the left side of the motorcycle, insert the water radiator connecting pipe ( ) to the expansion tank.

  • Page 360: Assembling Water Radiator

    Cooling system and lubrication system ASSEMBLING WATER RADIATOR On the right side of the motorcycle insert the radiator right support equipped with rubber bulb in the frame peg (A). Reinsert the sleeve (1) of the water input pipe of the radiator from the thermostatic valve.
  • Page 361 Cooling system and lubrication system Move the radiator towards the rear of the vehicle so that it can be inserted inside the sleeve (1) of the water suction tube of the radiator pump. Lower the oil radiator from the left-hand side and insert into the lower right fixing point of the water radiator.
  • Page 362 Cooling system and lubrication system Reposition the clamp (1) on the sleeve of the water inlet pipe to the radiator from the thermostatic valve and lock into place using the special pincer CLIC R 205 Specific tool - pliers CLIC R 205 Reposition the clamp (1) on the sleeve of the water suction pipe from the water pump to the radiator and lock into place using the special pincer CLIC R 205...
  • Page 363 Cooling system and lubrication system Insert the protective grid (1) in the proper seat. Assemble the plastic upper protection (1) and secure it using the two fixing screws. Position and tighten the oil radiator protection using the two fixing screws (1). - 27 -...
  • Page 364 Cooling system and lubrication system Position the water radiator side (1) protections secu- ring them on both sides using the respective fixing screws. Fill the system using the appropriate fluid. Fill until a level slightly over the notch indicating the MIN level is reached.
  • Page 365 Cooling system and lubrication system Reassemble the following components in order: - Air filter compartment - Fuel tank - Tank side panels - Rider’s saddle Start the engine for a few seconds. Let it cool and then re-check the level of the cooling liquid inside the expansion tank.

  • Page 366: Removing Oil Radiator

    Cooling system and lubrication system REMOVING OIL RADIATOR Before removing the oil radiator you should completely drain the lubrication system. Put an appropriate vessel under the engine. Remove the filling cap (1) on the right side of the motorcycle in order to facilitate the oil spill. Remove the filler cap (1) using the supplied 10 mm hexagon bar attached to a wrench.
  • Page 367 Cooling system and lubrication system Remove the engine-radiator support bracket fixing screw on the left side of the vehicle. Remove the oil radiator from the clamping rod on the right-hand side. Only if it is necessary replacing the oil radia- tor perform the follo ing operation.

  • Page 368: Reassembling Oil Radiator

    Cooling system and lubrication system REASSEMBLING OIL RADIATOR Only if it is necessary replacing the oil radia- tor perform the follo ing operation. Reposition the oil radiator and reconnect the oil deli- very and return pipes which are connected to the oil radiator by tightening the nuts, after having lubricated the relative threads beforehand with motor oil.
  • Page 369 Cooling system and lubrication system Reassemble the oil radiator protection securing it by the appropriate screws (1). Before replacing the cap, make sure it is thoroughly clean and replace the sealing ring with a new one. 35 N m On the oil drain plug there is a magnet for attracting any ferrous residuals which could form in the engine during the rotation.
  • Page 370 Cooling system and lubrication system Refill to the correct level. Close the oil filler cap. Before replacing the filler cap, grease the O-ring (1) with the silicon grease (see figure), then reposition in the proper seat. Tighten the cap (2) to the tightening torque indicated. Torque rench setting for oil drain plug 35 N m...
  • Page 371 Special tools SECTION Revision 1 - 1 -...
  • Page 372 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 373 Special tools Brutale Brutale Code Q.ty Note Descrizione Description I FRAME I I ENGINE I 990 R 1090 RR 800095830 • • Cavalletto anteriore Front stand 800091645 • • Chiave ghiera Steering bearing cuscinetti di sterzo pin wrench 800092857 • •...
  • Page 374 Special tools - 4 -...
  • Page 375 Special tools Brutale Brutale Code Q.ty Note Descrizione Description I FRAME I I ENGINE I 990 R 1090 RR 800092867 • • Attrezzo montaggio Equaliser pacco bilanciere pack tool 8000B4421 • • Attrezzo cuscinetti Front wheel ruota anteriore bearings tool 8000B1439 •...
  • Page 376 Special tools - 6 -...
  • Page 377 Special tools Brutale Brutale Code Q.ty Note Descrizione Description I FRAME I I ENGINE I 990 R 1090 RR 8A0094792 • • Attrezzo montaggio Gear change cambio mounting tool 800086119 • • Bussola di Locating bush riferimento 8000A1087 • • Cuscinetto Bearing 800098405...
  • Page 378 Special tools - 8 -...
  • Page 379 Special tools Brutale Brutale Code Q.ty Note Descrizione Description I FRAME I I ENGINE I 990 R 1090 RR 8000B2117 • • Cavo seriale Serial cable 8A00B2117 • • Cavo seriale Serial cable 8000B2118 • • CD-Rom per Power unit software centralina software CD-Rom 8A00B2118...
  • Page 380 Special tools - 10 -...
  • Page 381 Special tools Brutale Brutale Code Q.ty Note Descrizione Description I FRAME I I ENGINE I 990 R 1090 RR 8000B2051 • • Attrezzo fissaggio Exhaust screw vite scarico fixing tool 800079015 • • Attrezzo bloccaggio Clutch blocking frizione tool 8000A2280 •...
  • Page 382 Special tools - 12 -...
  • Page 383 Torque pressures SECTION Revision 1 - 1 -...
  • Page 384 SUMMARY TORQUE PRESSURES – CYCLE PARTS, EXCLUDING ENGINE - BRUTALE 990 R FRAME ............... . .PAGES 4-5 HANDLEBARS AND CONTROLS .
  • Page 385 Torque pressures - 3 -...
  • Page 386 Torque pressures - 4 -...
  • Page 387 Torque pressures - 5 -...
  • Page 388 Torque pressures - 6 -...
  • Page 389 Torque pressures - 7 -...
  • Page 390 Torque pressures - 8 -...
  • Page 391 Diagnostics SECTION Revision 0 - 1 -...

  • Page 392: Electrical Parts

    Diagnostics DIAGNOSTICS ELECTRICAL PARTS CHARGING SYSTEM Battery arning light on Defective alternator Substitute Defective alternator connection Check Defective battery Substitute Recharging fuse (40A) burnt out Substitute Defective recharging fuse connection Deoxidise/replace Oxidised battery connections Deoxidise/replace Defective voltage regulator connection Check Defective voltage regulator Substitute SERVICES ELECTRICAL SYSTEM 12V...
  • Page 393 Diagnostics Rear stop light does not function Fuse 6 burnt out Substitute Defective fuse 6 connection Deoxidise/replace Damaged tail light Substitute Defective tail light connections Deoxidise/replace Defective front brake lever switch Substitute Defective front brake lever switch connection Deoxidise/replace Defective rear brake lever switch Substitute Defective rear brake lever switch connection Deoxidise/replace...
  • Page 394 Diagnostics Reserve fuel arning light does not function Defective fuel level sensor Substitute Defective fuel level sensor connection Deoxidise/replace Defective instrument panel connection Deoxidise/replace Defective instrument panel Substitute Direction indicator arning light does not function Defective intermittency Substitute Defective intermittency connection Deoxidise/replace Defective instrument panel connection Deoxidise/replace...
  • Page 395 Diagnostics FRAME STEERING Steering is stiff Damaged steering bearings Substitute Steering bearings over-tightened Adjust Bent steering pin Substitute Steering shock absorbers brake too much Adjust Damaged shock absorber joint Substitute Low tyre pressure. Adjust The motorcycle does not proceed in a straight line Bent forks Substitute Bent frame...
  • Page 396 Diagnostics Rear suspension too rigid Excessive spring pre-loading Adjust Excessive hydraulic braking under compression Adjust Excessive hydraulic braking in extension Adjust High tyre pressure Adjust Damaged fork bearings Substitute Damaged compensator suspension bearings Substitute Damaged shock absorber joint Substitute Damaged connecting rod suspension joints Repair Bent fork pin Substitute...
  • Page 397 Analytical index SECTION Revision 1 - 1 -...
  • Page 398 Position of engine-control system parts (BRUTALE 990 R - 1090 RR) ... . .D-6 Lights ....... .B-85 Sensors .
  • Page 399 Switches ......E-38 – Front brake pads substitution .BRUTALE 990 R ....H-4 Chapter F - Suspensions and wheels –...
  • Page 400 Torque pressures - cycle parts, excluding engine BRUTALE 990 R ..... . .N-4-5 – Electrical system ....N-4-5 –...

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