MV Agusta BRUTALE 910 S Workshop Manual
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MV Agusta BRUTALE 910 S Workshop Manual

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MVAGUSTA BRUTALE 910 S
MVAGUSTA BRUTALE 910 S
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  • Page 1 MVAGUSTA BRUTALE 910 S MVAGUSTA BRUTALE 910 S Workshop engine manual...
  • Page 2 © 2005 The reproduction, even partial of this document is forbidden without prior written agreement of MV Agusta S.p.A. Part. N° 8A00A6440 - Edition N° 1 Printed – December 2005...
  • Page 3 Workshop engine manual MVAGUSTA BRUTALE F4 910 S...
  • 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 ..................ENGINE ........................- 3 -...
  • Page 7 General description SECTION Revision 0 - 1 -...
  • Page 8 General description SUMMARY HOW TO CONSULT THIS MANUAL ........... . .PAGE 3 THE PURPOSE OF THIS MANUAL .
  • Page 9 All information, instructions and technical data included in this manual are based upon information on the product updated at the moment of going to print. MV Agusta S.p.A. reserves the right to carry out changes at any moment with- out prior notice and without incurring any obligation.

  • Page 10: Glossary And Symbols

    General description GLOSSARY AND SYMBOLS During this kind of proce- All of the countersigns indicting right, N.B. ATTENTION dure inflammable vapours left, superior, inferior, front and back, might develop and metallic refer to the motor-bike in the normal parts might be expelled at direction of march.
  • Page 11 General description Use the recommended sealant. Use the recommended oil. Use the recommended grease. Use the recommended adhesive. Use the recommended brake fluid. Carry out accurate cleaning. Use the recommended suspension fluid. Use new components. Use the recommended coolant. Substitute the component. Use the recommended thread-locking Do not leave litter about.

  • Page 12: Right Hand And Left Hand Standard

    General description RIGHT HAND AND LEFT HAND STANDARD To clarify the right hand and left hand standard that is used in this manual, herewith below is a diagram of the motorcycle and the engine against which are indicated the right and left sides. Cylinder 2 Cylinder 3 Cylinder 1...

  • Page 13: Safety

    General description SAFETY The information contained in this paragraph is fundamental so that the operations carried ATTENTION out on the motorcycle can be conducted with minimum risk to the mechanic. Carbon Monoxide • Exhaust gases contain carbon monoxide (CO) that is poisonous. Carbon monoxide can cause the loss of con- sciousness and death.
  • Page 14 General description Brake fluid • Brake fluid is extremely corrosive. • Avoid any contacts with the eyes, skin and the mucous membrane. • If brake liquid comes into contact with the skin, remove all contaminated clothing and wash immediately with soap and water.
  • Page 15 • Slackening or tightening nuts or screws, always start with those of a greater dimension or from the centre. Always respect the torque values indicated. • Utilise only MV Agusta spare parts. INDEX GENERAL INDEX SUMMARY OF EACH CHAPTER...
  • Page 16 General description OPERATIVE TECHNICAL SPECIFICATIONS MOTORCYCLE IDENTIFICATION The registration number of the motorcycle is stamped on the right side of the steering head. The engine registration number is stamped on the upper engine casing, near the forks. 1) Frame registration number 3) Homologation date 2) Engine registration number Below is an example of the designation of the frame registration number:...
  • Page 17 Engine SECTION Revision 0 - 1 -...

  • Page 18: Table Of Contents

    Engine SUMMARY TABLE OF CLAMPING TORQUES ......................PAG. 3 PLANNED MAINTENANCE SCHEDULE ....................PAG. 5 THROTTLE BODY ADJUSTMENT AND TUNING..................PAG. 13 CYLINDER HEAD ............................PAG. 20 DISTRIBUTION CONTROL UNITS......................PAG. 24 CYLINDER AND PISTON GROUP ......................PAG. 44 CLUTCH ..............................PAG. 50 GEAR AND GEAR CONTROL ........................PAG. 57 ELECTRICAL COMPONENTS ........................PAG.

  • Page 19: Table Of Clamping Torques

    Engine TABLE OF CLAMPING TORQUES DESCRIPTION N·m Thread blockers HEAD Camshaft and gear screws strong Sliding block distribution screws medium Stand screws Valve cap screws Chain tightening screws Chain tightening cap CLUTCH Clutch nut medium Disk thrust plate screws GEAR SHIFT Pinion nut medium Gear selection drum tightening screws...
  • Page 20 Engine CLAMPING TORQUES TABLE DESCRIPTION N·m Thread blockers BEDPLATE Clutch cap M6 screws M6 bearing clamp screw medium Extractable gear change cap M8 screws M6 torque screws M8 torque screws Plate screws for oil radiator connectors Support screws for oil filter Inlet/outlet connectors for radiator oil medium CONNECTING ROD...

  • Page 21: Warning

    Let us help protect the environment Everything we do affects the entire planet and its resources. To protect the common interest, MV Agusta urges its customers and service operators to use the vehicles and dispose of their components in com- pliance with applicable regulations on environmental pollution control, waste disposal and recycling.
  • Page 22 Engine 1000 6000 12000 18000 24000 30000 36000 Frequency Km (mi) (600) (3800) (7500) (11200) (14900) (18600) (22400) Pre-delivery- Coupon Description Procedure Transmissions and flexible controls Check / Regulation Check / Regulation Drive chain Lubrification Substitution Check Pinion / Stop washer Substitution Every time drive chain is replaced Check...
  • Page 23 MOTUL CHAIN LUBE ROAD – * : MV Agusta recommends purchasing the product from its authorized dealers. The engine oil AGIP Racing 4T 10W/60 has been specially designed for the F4 engine. Should this lubricant be unavailable, MV Agusta recom-...
  • Page 24 Engine STANDARD ITEM WEAR LIMIT VALVES Ø Sealing external diameter +0,3 24,6 Exhaust......+0,3 28,6 Inlet........+0,2 Sealing face thickness..-0,3 Stem-guide clearance 0,02 ÷ 0,04 mm......Exhaust......Coupling : 0,10 mm 0,01 ÷ 0.03 mm......Inlet........0,08 mm mm......Ø...
  • Page 25 Engine STANDARD ITEM WEAR LIMIT CYLINDER AND PISTON ........... Piston ovalization....0,015 mm 0,038 ÷ 0,067 mm Piston-cylinder play....0,10 mm 0,004 ÷ 0,012 mm Piston-pin play......0,03 mm 0,015 ÷ 0,032 mm Pin-foot connecting rod play..0,06 mm Segment thickness -0,01 mm......
  • Page 26 Engine STANDARD ITEM WEAR LIMIT GEAR SHIFT 0,35 ÷ 0,15 mm......Gear fork-groove pivot play..0,65 mm 7,05 ÷ 7,15 mm....... Drum pit width......7,35 mm 6,8 ÷ 6,9 mm......Ø fork pivot......6,7 mm Minimum idle gear 0,10 mm axial play.........
  • Page 27 Engine Cleaning the parts All of the parts must be cleaned with special biodegradable solvents and dried with compressed air. Proceed with the cleaning process of all the parts before disassembling them as well as after the partic- ular parts have been disassembled. Clean each part even before reassembling.
  • Page 28 Engine Measuring compression in the cylinder The following tools are necessary in order to carry out this procedure: Spark plug key: n° 800089013 Compression measurer Adapter for the compression measurer. Heat the motor to the usual functioning tem perature (of regime); Switch off the engine, remove the tank, air box and sparkplugs;...

  • Page 29: Throttle Body Adjustment And Tuning

    Engine THROTTLE BODY ADJUSTMENT AND TUNING (Tickover check, CO synchronisation and check) Check and adjust First 1000 kilometres and then every 6000 kilome- tres The throttle body adjusting should be performed star- ting the engine of the motorcycle, therefore you should use a flue gas exhauster in order to not saturate the environment with burnt gas.
  • Page 30 Engine Verify the parameters of the injection-ignition system by the MDST diagnosis software. Connect the tool cable of the MDST diagnosis with the “Diagnostics” tap on the right side of the motorcycle near the expansion tank of the coolant. Start the MDST diagnosis software and go to the “Display instrument panel”...
  • Page 31 Engine Check the throttle angle when the throttle is completely closed. Huntings between 1.9° and 2.1° and between 2.3° and 2.5° are allowed only if the engine is started. A value above 2.5° is not allowed. If necessary adjust the throttle opening using only the appropriate screw on the throttle opening pulley.
  • Page 32 Engine Connect the depression pipes with the vacuometer complying with the match between the pipe and the cylinder which is connected to. In order to perform the following operations, you should provide with the specific tool kit for setting CO. Specific tool: Part code 8000A4686 Remove the sealing caps of the CO drives placed on...
  • Page 33 Engine Remove the seal plate and then the gearcase sealing cap. The by-pass screws must first be adjusted as follows: One and a half turns from the closed position Start the engine and warm it up. During this phase you should not accelerate because the high depression created in the induction lines could pipe the mercury from vacuometer.
  • Page 34 Engine Balance the pressures in the cylinders: the mercury columns must reach the same height. If all the parameters of the engine are set correctly, the position of the adjusting screws should be between 1 and 3.5 turns from the closed position. The number of turns per minute must fall within the fol- lowing values: 1150 ÷...
  • Page 35 Engine The attainment of the correct CO value could involve a variation of the engine speed at minimum. In this case you should operate the by-pass screws again to return the speed to the desired value and then repeat the trimmer adjustment. After having finished the adjustment operations, perform in the order as follows: - assemble the rubber plug on the gearcase lower side;...

  • Page 36: Cylinder Head

    Engine CYLINDER HEAD Tightening torque N·m Thread blockers Medium Sealant See text. Apply motor oil Apply silicone sealing NO OIL Do not apply neither oil nor other types of substances Apply HSC Molikote Apply grease Apply mastic for gaskets - 20 -...
  • Page 37 Engine Removal of Head group Remove the eight tightening nuts (1) and remove the valve cover (2) proceed carefully so as not to damage the gasket (3). When refitting, it is essential to apply silico- ne sealant as shown in the figure at the beginning of the chapter.
  • Page 38 Engine Remove the oil tube adduction and the head situated at the front of the motor, using the two tightening screw with a T number 8 key. Working on the phonic wheel knot with a number 19 mm bush key rotate the drive shaft up to the point where the n°...
  • Page 39 Engine Loosen the central screws of the chain tensioner distri- bution system. Remove the chain tensioner by means of the two tightening screws. First remove the 2 external stands (4 and 5) of the camshafts by means of the four screws each internally hexagonal.

  • Page 40: Distribution Control Units

    Engine DISTRIBUTION CONTROL UNITS NORDLOCK detail Tightening torque N·m Tipo Thread blockers Strong Medium Apply motor oil Apply silicone sealing NO OIL Do not apply neither oil nor other types of substances Apply HSC Molikote Apply grease Apply mastic for gaskets - 24 -...
  • Page 41 Engine In order to facilitate the detachment of the stands use a rubber hammer or delicately the end part of a flat screwdriver. Slightly rotate without force the unloaded end of the gearshaft shifting it from its slot; by doing so, the ten- sion on the distribution chain will loosen.
  • Page 42 Engine Remove the 12 tightening nuts from the head begin- ning from the external ones proceeding towards the internal ones, following the sequence indicated in the figure. On each encarcement there is a washer. Be carefully no to let it fall into the motor, you may block the holes with clean rags.
  • Page 43 Engine Remove the head and place it onto a clear place Remove the gasket which will be substituted during reassembly. Avoid placing the head upside down. Inspection of the head group Remove carbon deposits from the combustion cham- bers. Clean away eventual encrustments from the canalizations of the cooling liquid.
  • Page 44 Engine Head assy assembly To execute this operation you need the following spe- cial tool: A) n° 8000A3406 piston / cylinder plane distance measuring tool Place the new gasket on the cylinder plane. The gasket is of the same thickness of the one installed before if no parts replacement occurred.
  • Page 45 Engine Fit the gasket with the inscriptions facing up and the protrusion towards the march gear. Insert the centering bushes between the head and the cylinder. Positioning the head. Insert the washers on the encarcement if necessary with the help of a screw driver to guide them onto the internal encarcements.
  • Page 46 Engine Continue with the setting as follows: be sure that piston n° 1 is the MSP in burst phase; in this position “T” notch on the phonic wheel is in line with the reference notch on the bedplate. Remove the copper thread from distribution chain, keep the chain tightened.
  • Page 47 Engine Check and placement of distribution chain At each motor revision verify the wear state of each transmission distribution component. If the gear teeth appear to be very worn substitute each piece. Substitute the chain at the foreseen mileage. In case wear should result beyond the per- mitted allowance even of just one of the dis- tribution components, check them all and if necessary substitute them.
  • Page 48 Engine Pin number 1 Pin number 24 Pin number 25 - 32 -...
  • Page 49 Engine Insert the inlet camshaft so that the phase notch on the conveyer wheel is parallel to the head plane and facing the outside. Insert the exhaust camshaft with the notch placed between the 24th and 25th chain distribution gudgeon, beginning to count from gudgeon after the inlet camshaft notch.
  • Page 50 Engine Do not tighten the stand screws if the reac- tion springs are charged. Appropriately turn the camshaft so that the stand springs of which are to be tightened are uncharged and that the cams are positioned on the base radius.
  • Page 51 Engine Valve removel A)Take out the cups (1) with the help of a magnet and number them with a marker so as to reassemble them in the same position. B)Remove the tablets (2) of play adjustment with a magnet and place them inside the relative cup so as to reassemble them in the same position.
  • Page 52 Engine 800094798 - 36 -...
  • Page 53 Engine Maintenance of the valve slot Check the stroke surface [A] between the valve [B] and the slot [C] : no traces of pitting or cracks must appear. Measure the external diameter [D] of the stroke surface on the valve slot. If this should appear to be too elevated it is possible to repair the slot.
  • Page 54 Engine Substitution of the valve slot The following tools are necessary for this procedure: prick-puncher n° 800095319 for inlet slot prick-puncher n° 800095318 for exhaust slot Proceed as follows: A)Remove the worn slots carefully milling them so as not to damage the head lodging B)Check the lodging diameter on the head and choose the oversized valve slot considering that the assem- bling interference should be 0,10÷0,15 mm.
  • Page 55 Engine Valve guide check and maintenance 800095429 In order to carry out this procedure the following tools are necessary: Control tampon n° 800095429 Tampon n° 8000A2385 valve stem-valve guide play: 0,01÷0,03 mm inlet 0,02÷0,04 mm exhaust 0,08 mm inlet coupling limit : 0,1 mm exhaust 4,55 mm internal guide Ø...
  • Page 56 Engine Guide valve installation Assemble an oversized valve guide as follows: Oil the external valve guide surface. Slowly and evenly heat the cylinder head up to 150°. If necessary cool the valve guides with (N2) nitrogen liquid; or dry ice. Insert the valve guide using the special n°...
  • Page 57 Engine Valve-guide valve coupling Coupling play at assembly must be: 0,01 ÷ 0,03 mm inlet 0,02 ÷ 0,04 mm exhaust The maximum coupling limit permitted is even to 0,08 mm inlet 0,10 mm exhaust If a major play should result, substitute valve and valve guide.
  • Page 58 Engine Assembling the valve. 800095180 Insert in the order of: A)Insert the two coaxial springs B)Slide the semi cones into the superior disk slot and thus place the disk on the springs C)Assemble the head on the disassembling valve tool n°...
  • Page 59 Engine Regulating valve play Verify that the spark plugs have been disassembled. Should this procedure be carried out with the head assembled on the motor, block the spark plug holes with clean rags and assem- ble plate n° 800094797 to avoid the pieces accidentally falling into the chain distribu- tion opening.

  • Page 60: Cylinder And Piston Group

    Engine CYLINDER AND PISTON GROUP Tightening torque N·m Thread blockers Medium Apply motor oil Apply silicone sealing NO OIL Do not apply neither oil nor other types of substances Apply HSC Molikote Apply grease Apply mastic for gaskets - 44 -...
  • Page 61 Engine Removing cylinder and pistons Remove the cylinder head and rubber connecting rod between the cylinder and water pump as described in the relative paragraphs. Carefully slide out the cylinder group being careful not to damage the elastic strips. Work on one piston at a time to continue the removal. First remove the 2 pistons which are at the MSP and rotate the drive shaft at 180°...
  • Page 62 Engine Cylinder revision Check to be sure that enclosures show no sign of seizures with the pistons. Check piston ovalization in the following way: A)Measure the nominal diameter of each cylinder at a distance of 20 mm from the superior edge as indicated in the figure.
  • Page 63 Engine Piston-cylinder coupling The cylinder-piston groups are furnished already cou- pled; if there should be an exchange of cylinders and pistons between them it would be necessary to pro- ceed surveying coupling plays. Measure the diameter of the (ND) pipe at 20 mm from the superior plane, as indicated on the sketch.
  • Page 64 Engine Piston-pin connecting rod foot coupling Play between piston pin and connecting rod foot must be of 0,015÷0,032 mm. Maximum wear limit allowed 0,04 mm. Segments Verify the absence of lines and traces of shrinkage on each segment. Verify that the edge of the segment is well defined and free in the segments.
  • Page 65 Engine Cylinder and piston assembly The segments must be assembled on the piston with the writing Ne Top turned upwards and by following the outline in the figure. Oil the connecting rod foot and piston pin. Assemble the internal ring on the piston Insert the pistons complete with segments on the con- necting rods with the arrow facing the exhaust Insert the piston pins into the piston until beat.

  • Page 66: Clutch

    Engine CLUTCH 1 code 8000A2561 q.ty 7 2 code 8000A2562 q.ty 8 3 code 8000A2560 q.ty 2 4 code 8000A3379 q.ty 1 5 code 8000A3380 q.ty 1 Engine side Engine side Tightening torque N·m Thread blockers Average Apply motor oil Apply silicone sealing NO OIL Do not apply neither oil nor other types of substances Apply HSC Molikote...
  • Page 67 Engine The clutch release occurs using a postponing return group composed of a small thrust piston placed on the left side of the motor and operated by a hydraulic sys- tem. This small piston pushes a command rod which makes the disk pusher plate function.
  • Page 68 Engine Remove the disk pusher plate. If the friction rod must be slipped off, it is important to replace it from the cylindrical side of the friction control (left side of the engine) in order to prevent the oil seal (1) from damaging.
  • Page 69 Engine Remove the spacer (8) and shaving washer (9). Disassemble the clutch block following the sequence in the figure. - 53 -...
  • Page 70 Engine Clutch overhauling Check the rod for straightness and wear. Check the friction plates for wear. The standard thick- ness is 3 mm Maximum allowed wear limit : 2,8 mm. No signs of burning, grooves or other damages are allowed. Replace the whole plates group even if only one is damaged.
  • Page 71 Engine Clutch reassembly Reposition the shaving washer (9) with the smallest diameter facing towards the engine. Position the spa- cer (8), roller cage, friction drum and washer. Make sure the washer is positioned in front of the friction drum, since it was sheared and therefore has a sharp corner and a rounded corner.
  • Page 72 Engine It is recommended that a new safety washer and nut be used during reassembly. 140 N•m Tighten the nut at 140 N•m using a medium thread- locking product and then bend the safety washer. Assemble the disk pusher plate tightening the screws with springs as 10 N•m.

  • Page 73: Gear And Gear Control

    Engine GEAR AND GEAR CONTROL Tightening torque N·m 25 (M8) Thread blockers Medium Medium Medium Apply motor oil Apply silicone sealing NO OIL Do not apply neither oil nor other types of substances Apply HSC Molikote Apply grease Apply mastic for gaskets - 57 -...
  • Page 74 Engine Disassmbling gear group Remove the clutch following the instructions in the rel- ative paragraph. Remove the clutch rod from the clutch end. Remove the 6 tightening screws from the gear cap. Using a rubber hammer, delicately beat on the primary shaft from the clutch end holding a hand on the gear cap until it moves from the bedplate.
  • Page 75 Engine Gear command Disassemble the gear command group following the order shown in the figure. Place the various components in an orderly way so as to facilitate reassem- bling. Check each component for wear of irregular traces on its surface. Carefully check the following compo- nents.
  • Page 76 Engine Primary and secondary shaft Check the two shafts separate- ly so as to avoid confusion of similar components. Place the components in such a way as to facilitate the correct positioning dur- ing reassembly. - 60 -...
  • Page 77 Engine Gear group revision In order to carry out the following procedure the follow- ing special tool is necessary: Motor simulation utensil n° 8A0094792 Disassemble the gear group from the motor and reassemble it on the special utensil n° 8A0094792 motor simulator being careful to tighten the pinion fix- ing nuts with the separator that simulates the clutch hub.
  • Page 78 Engine Installation To execute this operation you need the following special tools: n° 8A0094792 gearbox tool Reassembly the various parts by acting in the opposite way. Install the 2 shafts on the n° 8A0094792 engine simulation tool. Install a shift pedal and check the gear box is correctly working.
  • Page 79 Engine All the gears must be inserted and unin- serted without stumbling. In case of stumbling, verify that the axial play has been correctly restored. With a thick meter verify that each gear- ing, once inserted presents a fork-pit play equal to 0,2 ÷ 0,3 mm placing it on both ends of the coupling.

  • Page 80: Electrical Components

    Engine ELECTRICAL COMPONENTS Tightening torque N·m Thread blockers Medium Medium Apply motor oil Apply silicone sealing NO OIL Do not apply neither oil nor other types of substances Apply HSC Molikote Apply grease Apply mastic for gaskets - 64 -...
  • Page 81 Engine Remove the pick-up from the phonic wheel. 25 N•m Alternator - Removal: Working on the left side of the motor, remove the three alternators and the stiffening stirrup tightening nuts. Slide the alternator out being careful not to let the rubber torsions fall.

  • Page 82: Oil Pump

    Engine OIL PUMP Tightening torque N·m Thread blockers Medium Apply motor oil Apply silicone sealing NO OIL Do not apply neither oil nor other types of substances Apply HSC Molikote Apply grease Apply mastic for gaskets - 66 -...
  • Page 83 Engine Remove the clutch and the gear as described in the relative paragraphs. Remove the seeger and the oil pump gearing. Remove the 3 tightening screws. Push the oil pump shaft from the gear end and slide the oil pump body from the clutch end. To disassemble the oil pump remove the external screws.

  • Page 84: Water Pump

    Engine WATER PUMP Tightening torque N·m Thread blockers Medium Apply motor oil Apply silicone sealing NO OIL Do not apply neither oil nor other types of substances Apply HSC Molikote Apply grease Apply mastic for gaskets - 68 -...
  • Page 85 Engine Removing water pump Work with cold motor. Drain liquid. A)Loosen the clamp and remove the coupling from the cylinder group,being careful not to damage it. B)Remove the screws (1) which fasten the pump body to the bedplate. C) Slide the pump out of the bedplate. Disassembling water pump pieces After having extracted the pump from the bedplate disassemble the pump as...
  • Page 86 Engine A)Heat the pump body (1) at 120°C. B)Remove the two bearings (6) with its relative space (7). C) Remove the seal ring. Revision of water pump pieces Verify that each component does not show any wear signs. In particular verify the flowness of the bearings and the O-Ring condition Verify that the impeller does not show signs of giving away or slits.
  • Page 87 Engine B)Insert the two bearings (6) with the relative spacer. C) After waiting for the pump body to cool, insert the seal and the counterface degreased in alcohol. Then insert the shaft with the impeller and rotating seal without touching the charcoal with oily hands. D)Insert the two seeger rings (3) E)Insert the two O-Rings (2) Be careful not to let the two centering bush-...

  • Page 88: Starting

    Engine STARTING Tightening torque N·m Thread blockers medium strong medium Apply motor oil Apply silicone sealing NO OIL Do not apply neither oil nor other types of substances Apply HSC Molikote Apply grease Apply mastic for gaskets - 72 -...
  • Page 89 Engine Free wheel starting Remove the clutch and gear indicated in the relative paragraphs. Slide out the intermediate starting gear pin, first disassemble the pin-blockage plate. Slide the intermediate gear. Slide the alternator flange and generator shaft out. If necessary disassemble the male torsion from the generator using tool 800094794 to unscrew the nut.

  • Page 90: Motor Shaft

    Engine MOTOR SHAFT Tightening torque N·m Thread blockers Medium See text Apply motor oil Apply silicone sealing NO OIL Do not apply neither oil nor other types of substances Apply HSC Molikote Apply grease Apply mastic for gaskets - 74 -...
  • Page 91 Engine Disassembling connecting rod Remove the driveshaft following the suggested proce- dure. Position the shaft with the connecting rod downwards. Work on each connecting rod separately. Loosen the two screws that tighten the foot of the con- necting rod and the head of the rod. Remove the two screws that sustain the connecting rod stem.

  • Page 92: Bedplate

    Engine BEDPLATE Tightening torque N·m 10+60° Thread blockers Medium Medium Medium Medium See text. Apply motor oil Apply silicone sealing NO OIL Do not apply neither oil nor other types of substances Apply HSC Molikote Apply grease Apply mastic for gaskets - 76 -...

  • Page 93: Caps

    Engine CAPS Tightening torque N·m Thread blockers Medium Medium Apply motor oil Apply silicone sealing NO OIL Do not apply neither oil nor other types of substances Apply HSC Molikote Apply grease Apply mastic for gaskets - 77 -...
  • Page 94 Engine Oil sump Disassembling and reassembling Remove the oil sump by unscrewing the 6mm fixing screws. Always substitute the gasket when reassembling. Check the condition of the oil intake filter and make sure that it is free of cracks or clefts; clean it by using compressed air at a low pressure, blown from inside to outside.
  • Page 95 Engine Position the gasket and move the screws close manu- ally. Tighten the sump screws to 10 Nm. 10 N•m - 79 -...
  • Page 96 Engine Disassembly Remove the oil filter with the relative support. Remove as follows as indicated in the relative para- graphs: A) The head B) The cylinder group C) The pistons D) The clutch E) The gear Remove: F) The size 6 screws including the one for the blow-by cap.
  • Page 97 Engine H)Separate the two carters (1 and 2) by manipulating the protrusions. I) If necessary remove the bearings (3). L) Slide the motor shaft out. In the event that the bushings should be temporarily removed (4) it is a good idea to identify the bearing number and its carter with a number using a marker.
  • Page 98 Engine Revision Once you have disassembled the motor shaft and in case there should be any doubt substitute the bench bushings as well as the connecting rod. Verify the motor shaft wear tolerance. The function play of the bench bearings must be between 0,012÷0,038 mm.
  • Page 99 Engine Laterally lubricate the n° 5 support as it carries out the function of the motor shaft centering. Put the new cap on the right side after having put the silicone type paste on the cap’s surface, between cap and carter bearing. Assembly the motor shaft.
  • Page 100 Engine Verify with a thick meter that the motor shaft has an axial play of 0,2 mm as regards the bench bearings. In case there should be different values contact the manufacturer. Reassemble the bearing on the inferior semi carter with the locks facing each other and turned inward the bedplate.
  • Page 101 Engine Insert the twelve size “8” screws (marked with the num- bers 1 to 12) and tighten them at 10 N·m + 60° while the remaining M8 are tightened at a torque of 25 N·m. Tighten the M6 screws at 10 N·m. Tighten all the screws inversely to the order they were disassembled.

  • Page 102: Lubrication Components: Oil Tubing Support Plate

    Engine LUBRICATION COMPONENTS: OIL TUBING SUPPORT PLATE Disassembling and reassembling To remove the oil tubing support plate, the oil filter sup- port should be removed first, as described in the “Oil sump” paragraph. Then, remove the oil head delivery conduit by remo- ving the lower and upper fixing screws respectively.

  • Page 103: Lubrication Components: Oil Filter Support

    Engine LUBRICATION COMPONENTS: OIL FILTER SUPPORT Reassembling Clean all the surfaces accurately and check the seal rings on the oil filter support screw as well as the O- rings for wear; substitute them, if necessary. Grease both the seal rings and the O-ring and position them in their seats respectively, as shown in the figure.
  • Page 104 Engine When reassembling, clean the surfaces accurately, 30 N•m and if the nipples have been removed from the oil tubing support plate, reassemble them by always inserting new copper washers between the nipple and the support plate. Screw the cylindrical end of the unions verifying that the conical side of each union has been left free.
  • Page 105 Engine Verify the O-rings placed on the oil head delivery con- duit for wear and substitute them, if necessary. When reassembling, grease both O-rings and position the upper part of the conduit in the seat arranged within the head and the lower part of the counduit in the seat arranged in the oil tubing support plate.

  • Page 106: Replacement Of Oil Filter

    - Toyo Roki oil filter kit: Part code 8000A3702 Only use original components of MV Agusta. Take a new rubber clamp from the motor’s oil filter kit and place it on the filter as shown in the figure to the left.
  • Page 107 Engine Insert the filter in its seat. Turn the filter manually until the gasket is into slight contact with the machined surface. Tighten the filter using the appropriate tool and a tor- que wrench. - TOYO ROKI oil filter: FACOM D. 139 tool Part code 8000A4317 Oil filter torque wrench: 24 N·m...
  • Page 108 Engine Place the clamp lock at a range of 2 mm from the screwhead on the supporting plate of oil cooler pipes. Tighten the screw of the clamp until it comes into con- tact with the filter, without tightening. Mark the screw position drawing a line by a felt-tip both on the screw and on the clamp.

  • Page 109: Lubricating Components: Oil Radiator

    Engine LUBRICATING COMPONENTS: OIL RADIATOR Disassembling Remove the engine/ radiator support fixing screw pla- ced on the left side. This figure and the next ones show an N.B. engine assembly which the water radiator has been removed from; but the described operations can be performed also when the radiator is assembled.
  • Page 110 Engine Reassembling Insert the support peg in the support (1) on the right side making the oil radiator move from left to right. Connect the engine/radiator anchor rod (1) on the left side. Put the radiator/engine support on the left side again and secure it tightening the screw.
  • Page 111 Engine If the pipes and connectors were removed from the radiator, replace them carefully by placing a wrench on the radiator to prevent the connectors of the radiator from tearing. Lubricate with threading of the connector with engine oil. Tighten the pipes and connectors at the prescribed torque.
  • Page 112 Part No. 8A00A6440 Edition No. 1...

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