MV Agusta F4 S Workshop Manual
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MV Agusta F4 S Workshop Manual

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Summary of Contents for MV Agusta F4 S

  • Page 2 © 2013 The reproduction, even partial of this document is forbidden without prior written agreement of MV Agusta S.p.A. Part no. 8A00B4301 - Edition no. 3 Printed – May 2013...
  • Page 3 Motorcycle workshop manual...
  • 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. 3 BODYWORK ......................Rev. 1 AIR INTAKE INJECTION SYSTEM ................Rev. 2 ELECTRICAL SYSTEM .................... Rev. 3 SUSPENSION AND WHEELS .................. Rev. 2 FRAME ........................Rev. 2 BRAKES........................Rev. 2 COOLING SYSTEM ....................
  • Page 7 General description SECTION Revision 0 - 1 -...

  • Page 8: Table Of Contents

    General description SUMMARY HOW TO CONSULT THIS MANUAL ........... . .PAGE 3 THE PURPOSE OF THIS MANUAL .

  • Page 9: How To Consult This Manual

    All information, instructions and technical data included in this manual are based upon information on the prod- uct updated at the moment of going to print. MV Agusta 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 ATTENTION incomplete Use the recommended suspension fluid. observance of this advice can be gravely dangerous for your safety and for the safety of other persons. This signifies that the lack Use the recommended coolant.

  • Page 11: 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 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: Index

    • Slackening or tightening nuts or screws, always start with those of a greater dimension or from the centre. Always respect the torque values indicated. • Utilise only MV Agusta spare parts. INDEX GENERAL INDEX SUMMARY OF EACH CHAPTER...

  • Page 15: Operative Technical Specifications

    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. 2) Engine registration number 1) Frame registration number 3) Homologation date Below is an example of the designation of the frame registration number:...
  • Page 16 General description - 10 -...
  • Page 17 Maintenance SECTION Revision 3 - 1 -...
  • Page 18 Maintenance SUMMARY TECHNICAL INFORMATION ............PAGE 3 TECHNICAL DATA (MY10 ->...

  • Page 19: Technical Information

    Maintenance TECHNICAL INFORMATION TECHNICAL DATA (MY10 -> MY12) Description F4 S F4 Frecce Tricolori F4 R F4 RR CHARACTERISTICS Wheelbase (mm) (*) 1430 1430 1430 1430 Total length (mm) (*) 2100 2100 2100 2100 Maximum width (mm) Seat height (mm) (*)
  • Page 20 Maintenance TECHNICAL DATA (MY10 -> MY12) Description F4 S F4 Frecce Tricolori F4 R F4 RR TIMING Type D.O.H.C. radial valves LUBRICATION Type Wet sump IGNITION - FUEL FEED SYSTEM Type “Magneti-Marelli” IAW 7BM integrated ignition-injection system with Mikuni throttle body;...

  • Page 21: Technical Data (My13)

    Maintenance TECHNICAL DATA (MY10 -> MY12) Description F4 S F4 Frecce Tricolori F4 R F4 RR At a speed lowerAt a speed higherAt a speed lowerAt a speed higherAt a speed lowerAt a speed higher At a speed lower At a speed higher...
  • Page 22 Maintenance TECHNICAL DATA (MY13) Description F4 R F4 RR TRANSMISSION Type Removable, six-speed gearbox with constant-mesh gears Gear ratios (total ratios) 2.643 (12.341) 2.643 (12.341) 2.643 (12.341) 2.062 (9.631) 2.062 (9.631) 2.062 (9.631) 1.722 (8.042) 1.722 (8.042) 1.722 (8.042) 1.500 (7.004) 1.500 (7.004) 1.500 (7.004) 1.318 (6.155)

  • Page 23: 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 24 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 Check / adjust Transmission and flexible controls Check / adjust Drive chain lubricate Substitution Check Front sprocket / stop washer Substitution...

  • Page 25: Maintenance And Tuning Operations

    D.I.D. CHAIN lUBE – * : To find the recommended product, MV Agusta suggests going directly to the authorised MV Agusta dealers. The eni i-Ride motoGP 10W/60 engine oil has been manufactured for the F4 engine. If the described oil is not...
  • Page 26 Maintenance Place a container underneath the engine to collect the used oil. Remove the oil discharge plug (1). Recover the oil in an appropriate container. Do not scatter the drainage oil into the envi- ronment. Allow the lubrication system to drain completely. Substitution of the oil filter Remove the 4 fixing screws (2) of the oil filter cover.
  • Page 27 Maintenance 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. Before replacing the cap, make sure it is completely clean.
  • Page 28 Maintenance Switch on the engine for several minutes. After switching off the engine, wait at least ten minutes and then check the oil level. Ensure that the motorcycle is placed on level ground and is in a vertical position. The correct level must be as close as possible to the “MAx”...

  • Page 29: Engine Coolant

    Maintenance ENGINE COOLANT Check / top-up level At the pre-delivery, at the first 1000 kilome- tres and then every 6000 kilometres. Keeping the motorcycle in a vertical position, check that the level of engine coolant is between the «MIN» and «MAx» mark found on the expansion tank (1). Max.
  • Page 30 Maintenance Manutenzione Engine coolant substitution Substitution every two years Before proceeding the emptying of the system, remove: The ignition switch cover (see “Engine coolant level check”); The under-engine fairing; left fairing panel (see chapter “Bodywork”); Place a container under the engine to collect the used coolant;...

  • Page 31: Electric Cooling Fans

    Maintenance Maintenance Check once again the level of the coolant inside the expansion tank, which should be between the «MIN» and «MAx» mark found on the expansion tank. If the level is inferior to the «MIN» mark, top up the coolant level by pouring new coolant into the filler hole.

  • Page 32: Valve Mechanism Adjustment

    Maintenance Maintenance VALVE MECHANISM ADJUSTMENT Check and adjust Every 12000 kilometres Remove in order the following components to carry out the measuring of the play between the camshaft and the valve cups: • left side fairing panel • lH fuel tank side panel •...
  • Page 33 Maintenance Maintenance - F4 MY10 -> MY12: Remove the locking bracket of the plug-top coils. Remove the 4 plug-top coils as shown in Chapt. G "Frame". - F4 MY13: Remove the fixing screws of the plug-top coils. Remove the 4 plug-top coils as shown in Chapt. G "Frame".
  • Page 34 Maintenance lift the front part of the motorcycle as shown in the figure. Remove the plastic covers (1) and remove the 8 fixing screws of the cover of the engine head (2). Remove the wiring clamps on the right side of the frame.
  • Page 35 Maintenance Disconnect the connectors shown in the figure. Remove the wiring from the frame. Operating as shown in the figure, slightly lift up the cylinder head cover. To carry out this operation, use only the work surfaces indicated. Take care to not ruin or deteriorate the motorcycle parts in the proximity of the work area.
  • Page 36 Maintenance Maintenance Proceed with the removal of the engine head cover as shown in the figure. Utilising a syringe, remove the surplus oil that is left in the various niches in proximity to the valve cups. Proceed with the removal of the timing wheel cover by unscrewing the five fixing screws.
  • Page 37 Maintenance Maintenance 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 Centre position (T.D.C.) when the piston is at its uppermost part of the compression stroke.
  • Page 38 Maintenance Maintenance Utilising a feeler gauge of the type shown in the figure, measure the play between the camshaft and the valve cups. The correct measuring of the play is a fun- damental operation for the correct function- ing of the engine. Carry out the measuring of the play of the following valves: Cylinders 1 and 2 intake valves...
  • Page 39 Maintenance 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 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 –...
  • Page 41 Maintenance 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 ÷...

  • Page 42: Spark Plugs

    Maintenance Maintenance Timing chain, mobile timing chain guide and timing chain tensioner Timing chain and mobile timing chain guide: Check Every 12000 kilometres Substitute Every 36000 kilometres Timing chain tensioner: Check / substitute Every 12000 kilometres To disassemble these parts and not being a part of nor- mal maintenance, it is necessary to proceed as described in the overhaul section of the F4 workshop engine manual (Part.
  • Page 43 Maintenance Maintenance Heat Grade Check the heat grade of the spark plugs. Sparks: - NGK CR9 EB DO NOT use non-resistive spark plugs. Spark plug gap If appropriate (see Technical Data table), measure the spark gap with a thickness metre. Adjust the gap if necessary on the basis of the following information: Spark plug Spark plug gap...

  • Page 44: Fuel Filters

    Maintenance Maintenance FUEL FILTERS Check and substitute Every 12.000 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: • Fuel tank side panels •...
  • Page 45 Maintenance Completely empty the fuel tank utilising a pump as illustrated in the figure. Petrol flange assembly removal Turn the tank upside down and remove the eight screws for fixing the flange to the tank (1). lift up the flange (1) and disconnect the tubes (2) on both sides of the flange.
  • Page 46 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 47 Maintenance 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 48 Maintenance 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 49 Maintenance 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 50: Fuel Pump Assembly

    Maintenance Maintenance FUEL PUMP ASSEMBLY - 34 -...
  • Page 51 Maintenance Maintenance Code Q.ty Note F4 S F4 FT F4 MY13 F4 R F4 RR I FRAME I I ENGINE I 8000B1958 • • • • • 8A00B1958 • • • • • 8000B4276 • • • • • 8000B4277 •...
  • Page 52 Maintenance Maintenance 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. Tighten the band fasteners by using the ClIC 205 pincers. Specific pliers: CLIC R 205 Part code 800095850 Gently press down the flange assembly into its seat...

  • Page 53: Fuel Tube Assembly

    Maintenance Maintenance FUEL TUBE / FITTINGS Check for leaks First 1000 kilometres and then every 6000 kilometres 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 54 Maintenance Maintenance ADJUSTMENT AND CALIBRATION OF THROTTLE BODY (MY10 -> MY12) After connecting to the control unit diagnostic software and before starting the engine, immediately check the throttle position: 2.3 degrees (min 1.9, max 2.6) If the position should not enter within the recommended field, reset with the TPS function, WITHOUT TOUCHING THE MECHANICAl ADJUSTMENT SCREWS OF THE THROTTlE.
  • Page 55 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 56 Maintenance The number of engine revs at idling should be kept at the following values: IDEAL 1150 rpm (min 1100 - max 1200) The system is able to balance engine running around the target speed 1150 rpm - 50 rpm acting automati- cally on the ignition advance.
  • Page 57 Maintenance ADJUSTMENT AND CALIBRATION OF THROTTLE BODY (MY13) Checking engine during idle The  engine control unit is designed to adjust the torque issued by the engine during idle. Set up the connection between the control unit and the TEXA diagnostic software. With the engine warm and the fans on, in idle, in neutral, observing the following parameters through the diagnostic software within the recommended intervals, you are able to control the...
  • Page 58 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 59 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 “Idle lead correction”...

  • Page 60: Air Filter

    Maintenance AIR FILTER Check/substitute Every 6000 kilometres Certain parts must be removed in sequence before acceding to the air filter. See chapter C “Bodywork”. • Seats • Right side panel tank • left side panel tank • Rear right side panel •...
  • Page 61 Maintenance Air filter disassembling (F4 MY10-> MY12) Unhook the two front clips (1) and remove the cover (2). Remove the filter (3). 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.
  • Page 62 Maintenance Air filter disassembling (F4 MY13) Unscrew the no. 7 fixing screws (1) and remove the air filter (2). Check the condition of the air filter. If it is necessary to substitute it, proceed as follows: Prepare a new air filter. Prepare the air filter by inserting a new gasket.
  • Page 63 Maintenance Maintenance Take the upper airbox cover and remove the gasket with the aid of a screwdriver. Position the gasket on the edge of the lower airbox. Position the upper airbox cover. - 47 -...
  • Page 64 Maintenance Maintenance Fasten the cover with four screws (two per side) (1). Proceed with the assembly of the parts listed below and according to the procedure described in chapter C “Bodywork”. • Fuel tank • left side airbox panel • Right side airbox panel •...

  • Page 65: Brakes And Clutch

    Maintenance Maintenance BRAKES AND CLUTCH Check the levels of fluid in the systems At pre-delivery, at first 1000 kilometres and then every 6000 kilometres. Check for leakages At pre-delivery, at first 1000 kilometres and then every 6000 kilometres. Substitute fluid Every 24000 kilometres or at least every two years Commands check...
  • Page 66 Maintenance Maintenance Before completing the operation, clean and wash accurately with alcohol the three components of the fluid chamber cover 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 67 Maintenance Maintenance Checking the level of the rear brake fluid No parts of the vehicle need to be removed from the vehicle to check the level of the rear brake fluid. If the fluid is below the low level mark, follow these steps to top up with brake fluid complying with the spec- ifications: remove the saddle and the fuel tank;...

  • Page 68: Brake/Clutch/Gearchange Commands Check

    The commands of the motorcycle are initially calibrat- ed to a standard position, but can be altered as follows. Front brake and clutch lever adjustment (F4 S - F4 FT - F4 MY13 - F4 R) Never carry out adjustments whilst riding the motorcycle.
  • Page 69 Maintenance Maintenance Whenever the command levers do not func- tion correctly or have excessive play, con- sult chapter H “Brakes” for the overhaul of the same. 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.

  • Page 70: Brake Pads

    Maintenance Maintenance Rotate the footrest support in the desired position. 34 ÷ 38 N•m Tighten the screw (1) at the prescribed torque pressure. Footrest support screw torque pressure: 34 ÷ 38 N . m Adjust both footrest to the same position. NOTE BRAKE PADS Wear check / substitute...

  • Page 71: Throttle Control (My10 -> My12)

    Maintenance Maintenance THROTTLE CONTROL (F4 MY10 -> MY12) Throttle control play check At the pre-delivery check, at the first 1000 kilome- tres and then every 6000 kilometres. The throttle control should not be too tight or too slack (excessive play) in its movement. It must also be free of play and looseness when turning it.

  • Page 72: Locks

    Maintenance Maintenance LOCKS Check At the pre-delivery, at the first 1000 kilometres and then every 6000 kilo- metres. Ignition/steering block switch This switch has four operating positions. Do not attach key rings or other objects to the ignition key that could obstruct the rota- tion of the steering.
  • Page 73 Maintenance 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. Let the key go free, bring it into a longitudinal position and pull it out.

  • Page 74: Steering

    Maintenance Maintenance STEERING Check and adjust At the first 1000 kilometres and then every 12000 kilo- metres. Check the steering components regularly according to the above-mentioned intervals. If it is necessary to carry out adjustments, operate as described in chapter F “Suspension and wheels”. TRANSMISSION CHAIN Check At the pre-delivery, at the first 1000...
  • Page 75 Maintenance Maintenance Regulation At the first 1000 kilometres and then every 6000 kilometres. To adjust the chain tension, proceed as follows: Slightly slacken the two screws of the rear wheel hub. Loosen the 2 rear wheel hub screws. Using the special spanner as indicated in the figure, move the eccentric adjuster nut backwards or forwards respectively slackening or tightening the chain, until the correct play is reached (as described previously).
  • Page 76 Maintenance Maintenance Chain lubrication Lubricate At the first 1000 kilometres and at 6000 kilometres and then at every 12000 kilometres. The chain is of the O-ring type. Clean the chain with a clean cloth and/or a jet of air. Apply the lubricant after cleaning. Utilise only the recommended lubricants or the equivalent (see page B-9).

  • Page 77: Tyres

    Tyre pressures PIRELLI - Diablo Supercorsa SP Brand and type DUNLOP - Sportmax Qualifier RR (F4 S / F4 FT) At a speed lower than 300 km/h At a speed higher than 300 km/h Front 2,3 bar (33 psi)

  • Page 78: Wheels

    Maintenance Maintenance WHEELS Visual check At the first 1000 kilometres and then every 6000 kilometres (at least every tyre change) After having visually checked or following even light collision damage, it is necessary to check the planari- ty, the eccentricity and the ovalisation of the wheel. See the control procedures described in chapter F “Suspension and wheels”.

  • Page 79: Rear Shock Absorber

    Spring adjustment standard A: - F4 S - FT - F4 R MY12 - F4 MY13: A = 170,5 mm - F4 R MY13 - F4 RR: A = 161 mm The shock absorber contains gas under high pressure.

  • Page 80: Side Stand

    Maintenance Maintenance SIDE STAND Functional check At the pre-delivery, first 1000 kilometres and then every 6000 kilometres Make sure the bike cannot be started when the stand is down and the bike is in gear. Also check that with the engine switched on, when the side stand is lowered and a gear is engaged, the engine switches off auto- matically.

  • Page 81: Front Forks

    The front fork is vitally important for the handling and stability of the motorcycle. It is therefore necessary to substitute the fork oil at the prescribed intervals. - Front forks (F4 S - FT - R - F4 MY13): 720 cc (*) Oil quantity:...
  • Page 82 If the warning light comes on even if the oil level is correct, do not resume riding and con- tact a MV Agusta authorized service centre. 6 Sidestand down warning light (red) Lights up when the sidestand is down.
  • Page 83 Maintenance Maintenance Multifunction display 10 Thermometer It displays the temperature of the coolant by turning on a variable number of segments on a graduated scale. When the temperature falls outside the nor- mal operating range, it may display one of the fol- lowing information: - the display shows just one blinking segment;...
  • Page 84 Maintenance 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) “TC” (Traction control) “CHRONO” (Chronometer) “NIGHT/DAY” (Night/Day Mode) “SETTING ÖHLINS” (Electronic suspension adjustment) (F4 RR MY13) “ABS”...
  • Page 85 Maintenance Maintenance “RUN” mode In addition to the speedometer, the display shows the following functions: • Total odometer “TOTAL” • Trip counter 1 “TRIP 1” alternatively: • Total odometer “TOTAL” • Trip counter 2 “TRIP 2” “TC” Mode This Mode adjusts the engine traction control level to your driving requirements.
  • Page 86 Maintenance “NIGHT/DAY” Mode This function enables the background colour of the dis- play to be converted in order to adapt its visibility depending on the time of day or night the vehicle is used. “SETTING öHLINS” Mode (F4 RR MY13) This mode allows to perform the adjustment of the fol- lowing elements: •...
  • Page 87 Maintenance Maintenance “QUICK SHIFT” Mode (MY13) This mode allows to turn off or on the “quick shift” func- tion of the gear change. Trip reset To reset “TRIP 1” and “TRIP 2”, proceed as follows. WARNING The display modes may be changed or set when the engine off, the gear in neutral, the motorbike stationary with your feet on the ground.
  • Page 88 Maintenance - Press the “OK” key for less than three seconds until the partial speedometer 2 function (“TRIP 2”) appears on the display. - By pressing the “OK” key for more than three seconds, the “TRIP 2” value will be reset to zero. “TC”...
  • Page 89 Maintenance - Press “SET” for less than three 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. Chronometer Lap timing acquisition - Turn on the chronometer (“CHRONO”...
  • Page 90 Maintenance - Press the headlight button again to record the time taken to cover the 1st lap. At the same time, the instrument starts recording the time taken to cover the second lap. The time measurement for the first lap is stored in the memory and is visualised on the display for ten sec- onds, after which the time measurement for the follow- ing lap appears.
  • Page 91 Maintenance - Press “OK” for less than three seconds until “LAPS VIEW” appears. - By repeatedly pressing “OK”, all the times previously acquired starting from the last lap memorised can be displayed in sequence. - Once all the data have been displayed, press the “SET”...
  • Page 92 Maintenance How to delete data To delete the saved data, proceed as follows: WARNING The display modes may be changed or set when the engine off, the gear in neutral, the motorbike stationary with your feet on the ground. Do not change the display while dri- ving.
  • Page 93 Maintenance - Subsequently, by pressing the flashing high beam headlight key followed by the “OK” key for more than three seconds, all the previously acquired times can be cancelled. - Once all the data have been cancelled, press the “SET” key to return to the “LAPS VIEW” mode and then to the following mode.
  • Page 94 Maintenance - Now, press “OK” for over three seconds to delete the value. Otherwise, press “SET” for less than three seconds to stop the deletion procedure. - Once all the data have been cancelled, the display shows “LAP TIME ERASED”, then returns to the “LAPS VIEW”...
  • Page 95 Maintenance - By pressing the “OK” key for more than three seconds, all the previously acquired times will be can- celled. By pressing the “SET” key for less than three seconds, the cancellation procedure will be interrup- ted. - Once all the data have been cancelled, the display shows “ALL LAPS ERASED”, then returns to the “LAPS VIEW”...
  • Page 96 Maintenance “IMMOBILIZER” function The "IMMOBILIZER" function allows the engine to be started up only after an original ignition key is recogni- sed. It is in fact an anti-theft system integrated into the electronic circuit of the vehicle, since it prevents use by any unauthorised individuals.
  • Page 97 “IMMOBILIZER”. Repeat the code entry procedure from the start, taking care of setting all the right digits shown on your MV Code Card. If the problem persists, contact a MV Agusta licensed service centre. - 81 -...
  • Page 98 Maintenance “SETTING öHLINS” Mode (F4 RR MY13) - In order to perform the customised adjustment of the suspensions setup, press “SET” to access to “SET- TING ÖHLINS” mode. WARNING The display modes may be changed or set when the engine is off, the gear in neutral, the motorbike stationary with your feet on the ground.
  • Page 99 Maintenance q Rebound damping (Front suspension) - After some seconds, the “FRONT” and “R” captions start blinking; it is now possible to modify the rebound damping value for the front suspension. - Press “OK” for less than three seconds: the rebound damping level rises up to the next value.
  • Page 100 Maintenance q Steering damper - After some seconds, the display shows the available modes for steering damper adjustment (“AUTO”: automatic; “MANUAL”: customised). - Press “OK” for less than three seconds; the “AUTO” caption will start blinking. - Press “SET” for less than three seconds; the “MANUAL”...
  • Page 101 The “ABS RACE” function has been expres- sly studied for use of the vehicle on race track. MV Agusta recommends not to use this function when riding on public roads. - If you do not press any button, after three seconds the “ABS RACE”...
  • Page 102 Maintenance “QUICK SHIFT” Mode (MY13) - Press “SET” in order to access to “QUICK SHIFT” mode. The display shows the current activation state of the “quick shift” function of the gear change. WARNING The display modes may be changed or set when the engine is off, the gear in neutral, the motorbike stationary with your feet on the ground.
  • Page 103 Maintenance How to select the mapping of the control unit (MY13) On F4 MY13 models it is possible to select different control unit mappings which allow to obtain variable power and performance characteristics based on the type of vehicle use. The mapping selection may be performed NOTE even during the use of the vehicle.
  • Page 104 Maintenance - Press “OK” for less than three seconds; the displayed setting will start flashing. - By repeatedly pressing “OK” for less than three seconds, the following settings can be displayed in sequence: • “NORMAL” • “RAIN” • “SPORT” - Press “OK” for more than three seconds; the new set- ting will be confirmed.
  • Page 105 Maintenance - Press “OK” for less than three seconds; the displayed setting will start flashing. - By repeatedly pressing “OK” for less than three seconds, the following settings can be displayed in sequence: • “SPORT” • “RAIN” - Press “OK” for more than three seconds; the new set- ting will be confirmed.
  • Page 106 Maintenance - Press “OK” for less than three seconds; the displayed setting will start flashing. - By repeatedly pressing “OK” for less than three seconds, the following settings can be displayed in sequence: • “NORMAL” • “SPORT” - Press “OK” for more than three seconds; the new set- ting will be confirmed.
  • Page 107 Maintenance - Press “OK” for less than three seconds; the displayed setting will start flashing. - By repeatedly pressing “OK” for less than three seconds, the following settings can be displayed in sequence: • “SLOW RESPONSE” • “FAST RESPONSE” - Press “OK” for more than three seconds; the new set- ting will be confirmed.
  • Page 108 Maintenance - Press “OK” for less than three seconds; the displayed setting will start flashing. - By repeatedly pressing “OK” for less than three seconds, the following settings can be displayed in sequence: • “NORMAL” • “SPORT” - Press “OK” for more than three seconds; the new set- ting will be confirmed.
  • Page 109 WARNING Whenever a fault is detected while the vehi- cle is running, stop running and contact an authorised MV Agusta service centre. - 93 -...
  • Page 110 If it is necessary to top up coo- ling liquid, contact an authorised MV Agusta service centre. If the indicator lights up even though the level is correct, do not con- tinue to run and contact an authorised ser- vice centre.
  • Page 111 Maintenance DEAlER MENU The instrumentation provides the opportunity to opera- te on an additional set of parameters. The auxiliary functions available are: • “SERVICE” (Scheduled maintenance expiration) • “UNIT CHANGE” (Changes unit of measurement) Viewing and editing modes of operation is performed in accordance with the procedures outlined in the para- graphs below.
  • Page 112 Maintenance - Press the "OK " button for less than three seconds until the message "SERVICE" is displayed. The mileage range with respect to expiration of the next scheduled maintenance is shown on this screen. - After performing scheduled maintenance, the mileage range must be reset using the following procedure.
  • Page 113 Maintenance “UNIT CHANGE” Mode This function allows for simultaneous editing of the fol- lowing units of measure: • Speed • Distance covered Changing the measurement unit - Access the "SERVICE" mode as described in the pre- ceding pages, and press the "SET" button for less than three seconds to until the message "UNIT CHANGE"...
  • Page 114 Maintenance - Press the "SET" button to pass from Km/h to Mph and vice-versa. Changing the unit of measurement on the speedometer automatically varies the following sizes: • Odometer (total and partial): Km –> mi If you press the "OK" button for longer than three seconds, the modification procedure of the measure- ment units will be interrupted.

  • Page 115: Lights

    Maintenance lIGHTS Check At the pre-delivery, at the first 1000 kilometres and then every 6000 kilo- metres. If any of the warning lights or the main lights are burnt out, replace them as follows. Driving/dipped beam - Bulb replacement To facilitate operations when replacing the NOTE driving/dipping beam bulb, it is advisable to remove the motorcycle beam.
  • Page 116 Maintenance Disconnect the connector. Connect the connector on the new bulb. Insert the new bulb, blocking it in position as shown in the figure. Caution: Do not touch the bulb glass with your hands. In case of contact, clean with a degreasing product.
  • Page 117 Replacing the license plate light bulb (F4 S - FT - R MY12 - RR MY12) - Remove the fixing screws of the lower cover of the license plate holder.
  • Page 118 Maintenance Maintenance - Extract the bulb socket sliding it from its seat. - Extract the bulb. - Insert the new bulb. - Reposition the bulb socket. - Reassemble the lower cover of the license plate holder. Caution: Before reassembling pay special attention to positioning the tail light harness correctly, in order to avoid any damage (see figure).
  • Page 119 Maintenance Replacing the license plate light bulb (F4 - F4 R - F4 RR MY13) - Remove the license plate light support fixing nuts. - Pull out the bulb holder and remove the license plate light support from the license plate holder. - Extract the burnt-out bulb from the bulb holder.

  • Page 120: Fuses

    Maintenance FUSES Battery recharge fuse - Replacement - The battery recharge fuse is located on the solenoid starter of the motorcycle. To expose it, remove the rider’s saddle. Solenoid starter CAUTIoN Turn the ignition key on the “oFF” position before checking or replacing the fuses, in order to avoid a short circuit with subse- Recharge fuse (40 A) quent damage to other electric parts of the...
  • Page 121 Maintenance Maintenance Service fuses - Replacement - The service fuses are located on the left side. To expose them, remove the side fairing - Release the two clamps and lift the fuse box cover. CAUTIoN Turn the ignition key on the “oFF” position before checking or replacing the fuses, in order to avoid a short circuit with subse- quent damage to other electric parts of the...
  • Page 122 Maintenance To identify the position and function of the fuses, refer to the information shown in the enclosed electrical diagram. The reference letters in the figure corre- spond to those shown in the diagram. Remember that the tool bag contains three spare fuses.
  • Page 123 Maintenance FRoNT HEADlAMP Check adjustment At every variation of the motorcycle set-up. The headlight should be adjusted every time the geometry of the vehicle is altered and before carrying a pillion passenger. The motorcycle is not equipped with external adjusters and the front projector unit is fixed to the frame.
  • Page 124 Maintenance - 108 -...
  • Page 125 Bodywork SECTION Revision 1 - 1 -...
  • Page 126 Bodywork SUMMARY FAIRING ASSEMBLY ............. . .PAGE 3 TAIL UNIT .

  • Page 127: Fairing Assembly

    Bodywork FAIRING ASSEMBLY Right side Left side • This exploded view demonstrates the position of the bodywork and the method of disassembly and assembly. - 3 -...
  • Page 128 Bodywork Fairing side panel removal Remove the seven fixing bolts (1) situated on the right fairing side panel. Remove the fairing side panel, sliding it off from the front side. Repeat the operation for the left fairing side panel. To separate the air manifold from the side panels, removing the two fixing screws (2).
  • Page 129 Bodywork Under-engine fairing removal Remove the three fasteners (1) placed respectively: 1 on the right side; 1 on the left side; 1 on the front central part; Remove the underfairing, sliding it off from the bracket (2). - 5 -...
  • Page 130 Bodywork Front fairing removal With a small flat-tip screwdriver, remove the connector (1) of the front headlight. Push the screwdriver forward to unhook the connector. Remove the two fixing screws (2) of the right rear-view mirror. Remove the connector and take off the right rear-view mirror (3).
  • Page 131 Bodywork Remove the two fixing screws (1) of the headlight fair- ing to the instrument panel support. Remove the two fixing screws (2) of the headlight fair- ing support on both sides. Remove the headlight fairing, sliding it toward the front part.

  • Page 132: Tail Unit

    Bodywork TAIL UNIT - 8 -...
  • Page 133 Bodywork Tail unit removal Insert the ignition key into the seat lock. Press lightly on the rear part of the passenger seat as shown in the figure. Turn the key and unlock the TAIL UNIT. Lift up the passenger seat. Press the driver seat release lever (1) and remove, sliding it from the rear part.
  • Page 134 Bodywork Remove the tank side fairings (1) on both sides, unhooking it from the pin and sliding it toward the rear part of the motorcycle (page C.12). Remove the right under seat side fairing removing the 5 screws (2). - 10 -...
  • Page 135 Bodywork Remove the side fairing toward the outside, taking care of the rear pin anchored in the support brackets. - 11 -...

  • Page 136: Fuel Tank

    Bodywork FUEL TANK - 12 -...
  • Page 137 Bodywork Side fairing removal Extract the left and right side fairing support as indicat- ed in the figure. Extract the rear part of the support first (A) then grad- ually withdraw the support from its front seat fixing (B). Remove the vent tube. Fuel tank removal Remove the rear fixing screw of the fuel tank (1).
  • Page 138 Bodywork Remove the two fixing screws (1) of the tank support bracket. Lifting the rear part of the tank, remove the bracket. Lift up the fuel tank. While lifting the tank take care not to dam- age the airbox. - 14 -...
  • Page 139 Bodywork Then position the special tank support tool in corre- spondence with the hole (1) on the seat seal and with the two tank support bracket fixing holes (2) on the rear frame. Special tool Code 8000B4414 Insert the tank on the tool support spindle as shown in the figure and disassemble electrical connections.
  • Page 140 Bodywork To disconnect the fuel tube, press and slide the retaining slide as shown in the figure. Disconnect the electrical system connector. Disassemble the duct cover panels Remove the two connecting screws (1) of the right panel (2) of the frame. - 16 -...
  • Page 141 Bodywork Lift the panel and unhook it from the two pins. Remove it outward. Repeat operations for the left panel. Disconnect the air temperature sensor connector. Remove the sensor electrical cable from the guides on the right duct. - 17 -...
  • Page 142 Bodywork From the left duct, remove the left direction indicator light electrical cable from the guides. Left and right air intake conduit removal Unhook the connector pin (1) on the ducts. Remove the right air intake conduit. Proceed with disassembly of the right air duct (2), turn- ing the front part outward.
  • Page 143 Bodywork Remove the right and left suction duct unions (1) before removing the airbox. Air filter compartment side panels Remove the left and right air filter compartment side panels by unscrewing the two relative screws (1). Before reassembly, check the integrity of the elastic nuts and replace if necessary.

  • Page 144: Air Intake System

    Bodywork AIR INTAKE SYSTEM - 20 -...
  • Page 145 Bodywork Airbox removal Remove the 4 fixing screws (2 per side) of the airbox cover. Remove the air box cover. Remove the cover by lifting it up. - 21 -...
  • Page 146 Bodywork - Only for F4 MY10 -> MY12: Remove the two fixing screws (1) of the control unit support plate and remove the plate. Unhook the clamp with the clip grippers on the valve of the TSS and disconnect the tube. Unhook the gas tube pressing the coloured button (1) to unhook it from the union (2).
  • Page 147 Bodywork Unhook the oil vapour tube. Lift the air box from its rear part, removing the rubber tube. Disconnect the upper injector cable connector. - 23 -...
  • Page 148 Bodywork Remove the cable. With the appropriate gripper, loosen the secondary valve tube clip and remove the tube. Lift and remove the airbox. - 24 -...

  • Page 149: Heat Shield

    Bodywork HEAT SHIELD - 25 -...
  • Page 150 Bodywork Heat shield removal After having removed the seats and the rear fairings as previously described, proceed as follows: Remove the silencers (see chapter F “Suspension and wheels”). Remove the battery (see chapt. E - electrical system). Remove the rear headlight connector fastening clip and disconnect the connector.
  • Page 151 Bodywork Remove the headlight support. Remove the 6 fixing screws of the heat guard. Lower and remove the guard toward the rear part. - 27 -...

  • Page 152: Mudguard - Central Spoiler - Radiator Protection

    Bodywork MUDGUARD - CENTRAL SPOILER - RADIATOR PROTECTION Right side Left side - 28 -...
  • Page 153 Bodywork Central manifold disassembly Remove the flashing relay (1) toward the rear part. Remove the two fixing screws (2) and remove the cen- tral manifold (3). Front mudguard disassembly Unscrew and remove the 4 fixing screws (1) on the mudguard (2 per side). - 29 -...
  • Page 154 Bodywork Remove the number plate holder toward the front part. Oil radiator protection disassembly Unscrew and remove the two screws (1), one per part. To remove the radiator protection, slide it downward removing the reference pin. - 30 -...
  • Page 155 Air intake injection system SECTION Revision 2 - 1 -...
  • Page 156 Air intake injection system SUMMARY INJECTION SYSTEM TECHNICAL CHARACTERISTICS ........PAGE 3 INJECTION TIME COMPENSATION (VOLUME) .

  • Page 157: Injection System Technical Characteristics

    Air intake injection system INJECTION SYSTEM TECHNICAL CHARACTERISTICS INJECTION TIME (INJECTION VOLUME) The factors for the determination of the injection time are the basic injection time that is calculated on the basis of the r.p.m. of the engine, the opening of the accelerator and various compensations that are determined accord- ing to signals coming from various sensors that reveal the condition of the engine and the riding conditions.

  • Page 158: Injection Time Compensation (Volume)

    Air intake injection system INJECTION TIME COMPENSATION (VOLUME) The various sensors allow the injection time (volume) compensations to be carried out on the basis of the fol- lowing signals. SIGNAL DESCRIPTION When the atmospheric pressure is low, the sensor ATMOSPHERIC PRESSURE SENSOR SIGNAL sends a signal to the ECU to reduce the injection time (volume).

  • Page 159: Fuel Feed System

    Air intake injection system FUEL FEED SYSTEM The fuel feed system is composed of tank, pump, filter, feed tube, feed tubes (including the fuel injectors) and pressure regulator. The fuel in the tank is pumped into the feed tubing at a controlled pressure by the relative reg- ulator and maintained at a certain constant value higher than the suction generated by the motor.

  • Page 160: Fuel Injector

    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 equal to the following value: - F4 MY10 ->...

  • Page 161: Fuel Pump Control System

    Air intake injection system FUEL PUMP CONTROL SYSTEM When the ignition switch is turned to the ON position, the fuel pump motor is started by the current supplied by the battery. As the CPU possesses a timer function, the pump motor stops turning three seconds after the ignition switch has been brought to the "ON"...

  • Page 162: Ecu (Electronic Control Unit)

    Air intake injection system The ECU consists of a CPU (Central Processing Unit), a memory unit and I/O sections (input/output). The signal of each individual sensor is sent to the input section and then to the CPU. On the basis of the sig- nals received, the ECU calculates the volume of fuel and the ignition advance necessary by utilising pre- pared schemes for the various conditions of the engine...
  • Page 163 Air intake injection system 2 INTAKE AIR TEMPERATURE SENSOR The temperature of the intake air is found by con- verting the resistance of the Thermistor into voltage and then sending it to the ECU. The volume of the injection increases when the air temperature is low. The resistance of the Thermistor increases when the air temperature is low and diminishes when the tem- perature is high.

  • Page 164: Throttle Body Position Sensor

    Air intake injection system THROTTLE BODY POSITION The sensor of the throttle position (1) is located in the centre of the throttle body. This sensor is a potentiometer with a resistance which varies according to the opening angle of the accelera- tor.
  • Page 165 Air intake injection system INJECTOR CHECK To check the injectors proceed as follows: - Disconnect a connector from one of the injectors. - Check between green-red and earth. For approxi- mately two seconds the voltage at the ends of the leads should be that of the battery.
  • Page 166 Air intake injection system - Check the functioning of the fuel pump, connecting respectively: Pin 1 of the connector to the + pole of the battery. Pin 2 of the connector to the – pole of the battery. - If the fuel pump unit does not continue to function correctly after the above-described tests, proceed with relative relay control (1) on the left side of the motorcycle, identified by a ring marked with "I"...

  • Page 167: 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 168: Diagnostics System (My10->My12)

    Air intake injection system DIAGNOSTICS SYSTEM (MY10->MY12) 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 169: Air Intake System Technical Characteristics

    Air intake injection system AIR INTAKE SYSTEM TECHNICAL CHARACTERISTICS This motorcycle utilises direct induction in the air intake system. The frontal pressure of the air during normal rid- ing conditions is conducted to the air filter compartment in such a way that the incoming air is pressurised there- by improving the air intake efficiency to obtain greater power from the engine.
  • Page 170 Air intake injection system SECONDARY AIR SYSTEM TECHNICAL CHARACTERISTICS (MY10 -> MY12) F4 bikes use an additional system for the secondary flow of induction air. Through this system, part of the air from the Airbox is channelled near the exhaust pipes of the cylinder through a set of on/off valves and passageways inside the engine head.

  • Page 171: Positions Of Engine-Control System Parts (F4 My10->My12)

    Air intake injection system POSITIONS OF ENGINE-CONTROL SYSTEM PARTS (F4 MY10 -> MY12) - 17 -...

  • Page 172: Positions Of Engine-Control System Parts (F4 My13)

    Air intake injection system POSITIONS OF ENGINE-CONTROL SYSTEM PARTS (F4 MY13) - 18 -...

  • Page 173: Injection System Electrical Diagram

    Air intake injection system INJECTION SYSTEM ELECTRICAL DIAGRAM FULE PUMP, INJECTOR FUSE COIL, ECU FUSE FUEL PUMP - COILS - INJECTORS RELAY MAIN RELAY SERVICE FUSE - 19 -...

  • Page 174: Engine Control Unit Pinout

    Air intake injection system Engine control unit pinout, MV Agusta F4 Connector Vehicle Engine Pin name Description of associated function Type Pin n° Pin n° IGN4 Output coil control N°4 OFA,LOW-SIDE IGN3 Output coil control N°3 OFA,LOW-SIDE SNSSPLY2_GND Analogic mass 2...
  • Page 175 Electrical system SECTION Revision 3 - 1 -...
  • Page 176 ELECTRICAL DIAGRAM (F4 S - F4 Frecce Tricolori) ....... . .

  • Page 177: 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 178: Semiconductor Parts

    Electrical system SEMICONDUCTOR PARTS • Do not drop semiconductor parts such as those INCORRECT incorporated in the ECU. • When checking these parts, carry out the instruc- tions to the letter. The lack of using the correct pro- cedure can cause grave damage. - 4 -...

  • Page 179: Electrical Diagram F4 S - F4 Frecce Tricolori

    Electrical system ELECTRICAL DIAGRAM F4 S - F4 Frecce Tricolori Gy/R L O C K PA R K O F F F1 F2 F3 F4 F5 F6 F7 58 59 60 61 5 9 12 8 2 3 6 7 4 11...

  • Page 180: Parts List

    Electrical system Parts list Parts list Ref. Description Ref. Description Ignition switch Safety and Front stop switch Number plate light Right indicator Right indicator Left indicator Front headlight Diagnostic connector Instrument panel Main relay Air pressure sensor Rear and stop light Left indicator Neutral switch Horn...

  • Page 181: Electrical Diagram F4 R - Rr My12

    Electrical system ELECTRICAL DIAGRAM F4 R - RR MY12 Gy/R L O C K PA R K O F F F1 F2 F3 F4 F5 F6 F7 58 59 60 61 5 9 12 8 2 3 6 7 4 11 4 3 2 1 3 2 1 R- O - F IGP L- O - R BATT R- O - R R- S W L- S W GND...

  • Page 182: Parts List

    Electrical system Parts list Parts list Ref. Description Ref. Description Ignition switch Safety and Front stop switch Number plate light Right indicator Right indicator Left indicator Front headlight Diagnostic connector Instrument panel Main relay Air pressure sensor Rear and stop light Left indicator Neutral switch Horn...

  • Page 183: Electrical Diagram F4 - F4 R - F4 Rr My13

    Electrical system ELECTRICAL DIAGRAM F4 - F4 R - F4 RR MY13 33 67 62 63 29 31 Gy/R L O C K O F F PRESS. IN_REL + IN_REL - R-Bk IN_CAMSHAFT Br-Y IN_GEAR_POS V-Gr IN_THROTTLE_POS_1A IN_THROTTLE_POS_2A Front Susp. Feedback (ABS) Rear Susp.

  • Page 184: Parts List

    Electrical system Parts list Parts list Ref. Description Ref. Description Front right indicator Front headlight Number plate light Rear right indicator Instrument panel Front left indicator Air pressure sensor Diagnostic connector Rear left indicator Main relay Horn Rear and stop light Air temperature sensor Neutral switch Light switch...

  • Page 185: Electrical Diagram F4 - F4 R - F4 Rr My13 (Abs)

    Electrical system ELECTRICAL DIAGRAM F4 - F4 R - F4 RR MY13 (ABS) 39 42 33 67 62 63 29 31 F10 F11 Gy/R L O C K O F F PRESS. IN_REL + IN_REL - R-Bk IN_CAMSHAFT Br-Y IN_GEAR_POS V-Gr IN_THROTTLE_POS_1A IN_THROTTLE_POS_2A...

  • Page 186: Parts List

    Electrical system Parts list Parts list Ref. Description Ref. Description Front headlight Instrument panel Number plate light Rear right indicator Air pressure sensor Front left indicator Rear left indicator Diagnostic connector Horn Main relay Air temperature sensor Rear and stop light Light switch Neutral switch Relay ballast headlight...

  • Page 187: Battery

    Electrical system BATTERY The battery mounted on this motorcycle is a sealed battery therefore no maintenance is required. The following battery is used: KOYO KTZ-10S This is a sealed battery with breather valve. No elec- trolyte level checking is required. Never remove the battery seal caps nor block the breather opening.

  • Page 188: Battery Assembly

    Electrical system BATTERY ASSEMBLY 1) Perform the initial charge of the battery according to the instruction shown in page 13. 2) Insert the motorcycle key in the rear lock. Rotate the key clockwise while removing the pillion. Then remove the rider’s saddle as shown in the picture.
  • Page 189 Electrical system 5) Insert the battery in its proper compartment. 6) Fit the 2 positive terminals (+) on the corresponding battery pole, respecting their disposition as shown in the figure. Rotate the positive terminals screw and tigh- ten it at a torque equal to 7 ÷ 8 Nm. Afterwards, fit the protective cap on the positive pole.
  • Page 190 Electrical system Wait at least twenty-four hours before positioning the battery in the compartment. This is strictly necessary for this motorcycle as the battery is positioned horizontally, as shown in the diagrams below. • Check the voltage charge after about thirty minutes at the battery terminals.

  • Page 191: Battery Recharge

    Electrical system BATTERY RECHARGE The battery is charged by connecting the supplied bat- tery charger to the connector located under the pas- senger seat. If the battery is charged after a period of vehicle downtime, make sure that the charger fuse is placed inside its housing on the remote ignition switch.

  • Page 192: Recharging System

    Electrical system CHARGING SYSTEM Warning function Conditions of abnormal operation of the battery char- ging function (voltage 10V) is indicated by the war- ning lamp on the dashboard. ≥ As shown in the figure, the temperature influences the characteristics of the regulator with steps of variation of the regulated voltage.
  • Page 193 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 NECTION WITH CONNECTION...

  • Page 194: Efficiency Check

    Electrical system BATTERY EFFICIENCY CHECK Battery current loss check • Remove the seats as described in chapter C “Bodywork”. • Turn the ignition switch to the “OFF” position. • Disconnect the cable from the negative (-) pole of the battery. •...

  • Page 195: Starter System

    Electrical system Measure the DC voltage between the positive (+) and the negative (-) terminals of the battery with a multi- tester. If the tester indicates less than 12.6V or more than 14.5V the cause will be found in the generator. Battery When carrying out this check, ensure that NOTE...
  • Page 196 Electrical system FULE PUMP, INJECTOR FUSE COIL, ECU FUSE FUEL PUMP - COILS - INJECTORS RELAY MAIN RELAY SERVICE FUSE - 22 -...
  • Page 197 Electrical system FULE PUMP, INJECTOR FUSE COIL, ECU FUSE FUEL PUMP - COILS - INJECTORS RELAY MAIN RELAY SERVICE FUSE - 23 -...
  • Page 198 Electrical system FULE PUMP, INJECTOR FUSE COIL, ECU FUSE FUEL PUMP - COILS - INJECTORS RELAY MAIN RELAY SERVICE FUSE - 24 -...
  • Page 199 Electrical system - 25 -...
  • Page 200 Electrical system - 26 -...
  • Page 201 Electrical system - 27 -...

  • Page 202: Starter Motor Removal

    Electrical system STARTER MOTOR REMOVAL (MY10 -> MY12) • Remove the fuel tank (see chapter C “Bodywork”). • Drain off the engine coolant, completely emptying the cylinder passageways via the two screws situat- ed on the front part of the cylinders. •...

  • Page 203: Starter Motor Assembly

    Electrical system STARTER MOTOR ASSEMBLY Assemble the starter motor in the reverse order of removal. Pay attention to the following points: Substitute the O-ring with a new one to avoid oil leakage and the ingress of humidity. • Apply grease to the oil seal lip. •...
  • Page 204 Electrical system • Disconnect the start-up relay connector. • Disconnect the cables from the negative pole of the battery to avoid short circuits during assembly. • Disconnect the cables of the starter motor and the positive cable of the battery from the relay. - 30 -...

  • Page 205: Tilt Sensor (My10->My12)

    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.

  • Page 206: Gear Position Switch

    Electrical system GEARCHANGE POSITION SWITCH The connector (1) of the gear position sensor is loca- ted 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 207: Fuses

    Electrical system Utilising a multi-tester, check the continuity as indica- ted in the table. Green Brown Black ON (Raised) OFF (Lowered) After the tests described above, whenever it is neces- sary to replace the switch, proceed as indicated in chapter B Maintenance. FUSES The fuses are situated on the left side of the motorcy- cle.

  • Page 208: Spark Plugs

    Electrical system The charge fuse is situated under the seat, in the posi- tion indicated on the starter relay. To accede to this component it is necessary to remove the following parts: Spare fuse • The driver’s seat; • Remove the plastic covers on both fuses. •...

  • Page 209: Main Relay

    Electrical system Check the resistance between the electrode and the screw cap of the spark plug as shown in the figure. Permitted resistance: 4.5 ÷ 5.5 K Carry out the test on all the spark plugs. Do not use non-resistive spark plugs.. MAIN RELAY The main relay is situated on the left side and it is iden- tified by the “M”...

  • Page 210: Engine Pick-Up

    Electrical system ENGINE PICK-UP The engine pick-up is situated on the left side of the motorcycle. To check this component it is necessary to identify the relative connector positioned as shown in the figure, inside the frame on the left side of the motor- cycle.

  • Page 211: Timing Wheel Gap

    Electrical system TIMING WHEEL GAP To guarantee the correct functioning of the pick-up it is necessary to measure the gap between the pick-up and the timing wheel by utilising a feeler gauge as shown in the figure. Gap width: 0.6 – 0.7 mm To carry out this check it is necessary to remove the cover of the timing wheel by consulting the Workshop Engine Manual.

  • Page 212: Instrumentation

    Electrical system Remove the connector holding device. With the switch in the “RUN” position, check the conti- nuity between pins (5) and (2). INSTRUMENTATION F4 MY10 -> MY12 If faults are found in the instrumentation, it is necessary to check the main wiring and the various components assisted by the same instrumentation.

  • Page 213: Oil Pressure Sensor

    Electrical system Consult the diagram below to identify the contacts of 16 pin AMP 174975-2 the various components: Supply ID warning led 10 Oil pressure + CAN 11 Ignition key - CAN 12 Serial Tx 13 Serial Rx High beam 14 Immobilizer Fuel warning led 15 Immobilizer Hazard out...

  • Page 214: Water Sensor

    Electrical system Having ascertained the good condition of the fuses in question, proceed as follows: With the fuel tank removed from the motorcycle and empty of fuel, connect a small circuit composed of 12V battery and a light bulb of 12V – 1.7W to the connector of the fuel level indicator as shown in the diagram.

  • Page 215: Turn Indicators Check

    Electrical system KEY SWITCH Whenever the dashboard, with the switch on the ON position, is not powered, first check the conditions of the fuse located on the start-up remote switch under the seat and, if this should be in good condition, check the conditions of the fuse located in position 1 on the fuse box.

  • Page 216: Intermittence Relay

    Electrical system INTERMITTENCE RELAY The intermittence relay (1) is placed on the front part of the motorcycle, upon the central conveyor. DIAGNOSTICS UNIT The diagnostics connector (2) is placed under the pas- senger’s saddle. With the ignition key in OFF position, remove the pro- tecting cap from the connector and connect it to the diagnostics unit.

  • Page 217: Abs Unit (My13)

    Electrical system ABS* UNIT (MY13) The unit of the ABS system (1) is placed under the pas- senger’s saddle. (*): This function is present only on certain models ELECTRONIC SUSPENSIONS UNIT (F4 RR MY13) The unit for the management of the electronic suspen- sions (2) is placed on the left intake duct.

  • Page 218: Low Beam Headlight

    Electrical system LOW BEAM HEADLIGHT F4 MY10 -> MY12 MY10 -> MY12: In the event that the dipping beam does not work, check the conditions of fuse 3 on the fuse box. If this fuse is ok, check the conditions of the relay placed on the left side of the motorcycle, with the label "B".
  • Page 219 Electrical system If the fuse is ok, check the continuity of the left handle- bar control connector between positions 1 and 10 with the driving beam function selected. If this is also ok, the problem can be attributed to the headlight unit.

  • Page 220: Turn Indicators

    Electrical system TURN INDICATORS In the event that turn indicators do not work, check the conditions of following fuse: Fuse 1 - MY10 -> MY12: Fuse 6 - MY13: If the fuse is ok, check the continuity between Gr-Bk/W (Green-Black/White) and Gr-Y/W (Green-Yellow/White) wires respectively for left and right indicators on the connector of the left switch.

  • Page 221: Horn

    Electrical system COOLING FAN SYSTEM If there is a fault in the functioning of the cooling fan, proceed with the following check: • Check the condition of the following fuse: Fuse 5 - MY10 -> MY12: Fuse 7 - MY13: •...

  • Page 222: 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. R.H. switch L.H. switch - 48 -...

  • Page 223: Positioning Of Electrical System Wire Clamps (F4 My10 -> My12)

    Electrical system POSITIONING OF ELECTRICAL SYSTEM WIRE CLAMPS (F4 MY10 -> MY12) LIST OF FASTENING CLAMPS FOR F4 1000 ELECTRICAL SYSTEM CABLES Code Qty. Length Name 800092248 L = 82 mm Rubber clamp L 82 800092247 L = 62 mm Rubber clamp L 62 800053724 L = 39 mm...
  • Page 224 Electrical system Insert 1 protective clamp (Code 8000B4230) on the throttle body clamps present on the right side of the motorcycle (see Fig. 03). Protective clamp Code 8000B4230 Note: Be careful to correctly position the node and the TPS cable For the position of the clamps for fastening electri- cal system F4 1000 cables, refer to the layout shown below (see figs.
  • Page 225 Electrical system Note: Be careful to correctly pass cables Code Code Note: Be careful to correctly pass cables - 51 -...
  • Page 226 Electrical system Code Code Code Note: Be careful to ensure correct assembly phasing of the cable lug Note: Be careful to correctly pass cables and the blow-by hose - 52 -...
  • Page 227 Electrical system Code Note: Position the branching node on the right side of the frame Note the correct passage of vacuum gauge tubes on both the left and right sides of the motorcycle (see figs. 09-10). - 53 -...
  • Page 228 Electrical system - Position 1 adhesive protection code 8000B4924 on the front right side frame tube, first applying the upper edge as shown in Fig.11. Protection (Code. 8000B4924) - Wrap the adhesive protection around the frame tube and complete application taking care to stretch it evenly to avoid air bubbles (see Fig.
  • Page 229 Electrical system Screw cap Code Code (Code 800094896) Note: be careful to correctly pass cables Note: Be careful to Code correctly position Code cables - 55 -...
  • Page 230 Electrical system Code Note: Be careful to correctly pass cables Note: Be careful to correctly pass cables Code Note: Be careful of the Code burr on the engine casing Note: Be careful of the burr on the oil pan gasket Note: Be careful to correctly pass cables...
  • Page 231 Electrical system Code Code 800056783 (plastic) Code 3-way rear headlight AMP connector Code 800056783 Rear indicator + (plastic) Number plate light - 57 -...
  • Page 232 Electrical system Note: Be careful to correctly pass Code cables Code Note: Position the wiring node at the Code beginning of the weld bead Code Protection sheat Code Wiring protection Note: Slip off the Code 8000B4776 wiring sheath until (Assemble with it reaches the posi- LOCTITE 5900) tion indicated...
  • Page 233 Electrical system Note: Be careful to correctly pass cables Note: Be careful to correctly pass cables - 59 -...

  • Page 234: Positioning Of Electrical System Wire Clamps (F4 My13)

    Electrical system POSITIONING OF ELECTRICAL SYSTEM WIRE CLAMPS (F4 MY13) - 60 -...
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  • Page 251: Positioning Of Electrical System Wire Clamps (F4 My13 Abs)

    Electrical system POSITIONING OF ELECTRICAL SYSTEM WIRE CLAMPS (F4 MY13 ABS) - 77 -...
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  • Page 257 Suspension and wheels SECTION Revision 2 - 1 -...
  • Page 258 Suspension and wheels SUMMARY FRONT WHEEL ..............PAGE 3 FRONT FORKS .

  • Page 259: Front Wheel

    Suspension and wheels FRONT WHEEL N· m 20 ÷ 22 (F4 S - FT 40 ÷ 44 (F4 S - FT F4 R - F4 MY13) F4 R - F4 MY13) Torque 19 (F4 RR) 60 ÷ 65 (F4 RR) pressure Kg·...
  • Page 260 Suspension and wheels FRONT WHEEL REMOVAL Place the motorcycle on the rear stand. Special tool N. 800092642 Front brake caliper removal Unscrew the two fixing screws of both front calipers and remove the calipers. Protect the disassembled calipers with pro- tective material thereby avoiding possible damage to the wheel rim.
  • Page 261 Suspension and wheels Front wheel removal (F4 S - F4 FT - F4 MY13 - F4 R) Remove the screw on both front wheel/fork attach- ments. During this operation, it is necessary to support the wheel. Open the terminals (1) and remove the wheel with its spindle.
  • Page 262 Suspension and wheels Front wheel bearing check Preliminary operations (only for F4 RR): - Fit the axle on the front wheel. - Turn in and bring the threaded bushing (Code no. 80A0A3469) into contact with the wheel spindle, tigh- tening it by hand. With the wheel spindle still mounted to the wheel, rotate the wheel to check that the bearings are not pit- ted and rotate with a smooth action.
  • Page 263 Suspension and wheels Introduce the extractor until the internal ring of the bearing is hooked up. Introduce the wheel spindle and screw and 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 264 Suspension and wheels Reassembly – front wheel bearings Before proceeding with the reassembly, accurately clean the bearing seats in the wheel hub. Lubricate the outer ring of both bearings with special grease. Mount the bearing on the specific tool and insert it in the rim housing.
  • Page 265 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 266 88. - Front wheel assembly (F4 S - FT - R - F4 MY13) After having carried out the check on the parts of the front wheel, accurately clean the wheel spindle and assemble it from right to left.
  • Page 267 Tighten the two screws (1) of the fork feet to the torque pressure prescribed. Fork foot screws torque pressure: F4 S / FT / R / F4 MY13: 20 ÷ 22 N·m F4 RR: 19 N·m During the operation, support the front wheel so as to prevent the screws from sticking.

  • Page 268: Front Fork

    Suspension and wheels FRONT FORK (F4 S - F4 FT - F4 R - F4 MY13) N· m 20 ÷ 22 8 ÷ 10 8 ÷ 9 16 ÷ 18 22 ÷ 24 Torque Kg· m pressure ft· lb Operation...
  • Page 269 Suspension and wheels FRONT FORK OVERHAUL (F4 S - F4 FT - F4 R - F4 MY13) Before removing and overhauling the front suspension components, it is advisable to remove the lower fairing, the left and right fairings, the front cowl, the air ducts,...
  • Page 270 Proceed with the same operation for both stems. Fork tube exploding (F4 S - F4 FT - F4 R - F4 MY13) Place the fork leg in a vice, taking care to protect its surface against possible damage.
  • Page 271 Suspension and wheels Completely unscrew the plug and lower the sheath as shown in the figure. Perform this operation while hold- ing the leg in a vertical position. Unscrew the plug. Using the spanner, adjust the spring preload while locking the nut on the damping piston rod.
  • Page 272 Suspension and wheels Remove the spring together with the spacer. Remove the inside rebound adjusting rod. Turn the stem upside down and completely pour out the oil into a suitable container. Recover the oil in an appropriate container. Do not dispose of the used oil in the environ- ment.
  • Page 273 Suspension and wheels Pull out the damping piston. Take care not to reverse the pumping elements on the fork while fitting it back in, and configure as follows: - Brake-pressing pumping element: fit on left fork. - Brake-releasing pumping element: fit on right fork. Lower dust cap (1), taking care not to damage the seat on the sheath.
  • Page 274 Extract the fork leg with repeated jerks at the end of its travel. Fork assembly check (F4 S - F4 FT - F4 R - F4 MY13) Check that the sleeve does not have marks on the external part that could have repercussions inside the assembly.
  • Page 275 Suspension and wheels Assembly oil seal and anti-dust seal (F4 S - F4 FT - F4 R - F4 MY13) After having carefully checked all components, substi- tute those damaged and/or deteriorated. Grease the lips of the new anti-dust seal (1) and the new oil seal (2) with the appropriate grease.
  • Page 276 Check that the oil is at level "X" with reference to the upper fork leg rim, measured when the fork is com- pletely compressed. - F4 S / FT / R / F4 MY13 (**): X = 70 mm (**): N.B.: Measured with the pumping rod at the end of its stroke and the spring spacer in.
  • Page 277 Suspension and wheels Manually turn the counternut in to the end of the threaded portion. The counternut is characterized by a special fitting direction. Ensure that the two span- ner resting surfaces are facing up (see fol- lowing figure). Fit in the spring. Fit the spanner to damping piston nut (1), pressing down slightly on the spring.
  • Page 278 Suspension and wheels Tighten the plug with the prescribed torque. 20 N•m Fork leg plug tightening torque: 20 N•m Insert and screw in the complete cap (1) on the fork sli- der. FRONT FORK OVERHAUL (F4 RR) Refer to a Öhlins authorized assistance cen- ter in order to perform the substitution of the oil inside the stems and the complete revi- sion of the front forks.
  • Page 279 To ensure proper positioning of the rods, refer to the figure at right, taking care to observe fitting dimension "X": - F4 S / FT / R / F4 MY13: X = 212 mm - F4 RR: X = 219 mm Screw in and tighten the three screws (1) at the base of the steering.
  • Page 280 (3). Torque pressure - Steering head screws (2): - F4 S / FT / R / F4 MY13: 16 ÷ 18 N·m - F4 RR: 18 ÷ 22 N·m Torque pressure - Central screw (3): 22 ÷ ...
  • Page 281 Suspension and wheels Tighten the screws (1) to the prescribed torque pres- sure. After having carried out the assembly of the right clip-on handlebar, check that the accelerator handgrip rotates freely and smoothly. Grease only the first threads. Torque pressure: 8 ÷ 10 N·m 8÷10 N•m Replace the brake line holding clamps.
  • Page 282 Suspension and wheels Front suspension adjustment Rebound damper (F4 S - FT - R - F4 MY13) Refer to values contained in the table to adjust front suspension. Spring preload Spring preload Compression damper Adjustments contained in the table must...
  • Page 283 Suspension and wheels Front suspension adjustment Rebound damper (F4 RR MY12) Refer to values contained in the table to adjust front suspension. Spring preload Spring preload Compression damper Adjustments contained in the table NOTE must be carried out from initial referen- Spring ce positions: preload...
  • Page 284 20 clicks Compression damping 13 clicks 12 clicks 18 clicks (*): To use the vehicle in this configura- NOTE tion, MV Agusta suggests to increase Spring the rear suspension spring preload of 1 preload mm (see page 85 of this chapter).

  • Page 285: Steering Assembly

    Suspension and wheels STEERING ASSEMBLY N· m 120 ÷ 125 16 ÷ 18 8 ÷ 10 4 ÷ 6 22 ÷ 24 22 ÷ 24 8 ÷ 10 In contact -F4 MY13) +10° 18 ÷ 22 Torque (F4 RR) pressure Kg·...
  • Page 286 Suspension and wheels STEERING ASSEMBLY OVERHAUL Lift the motorcycle and rest it on the special tool. Special tool No. 8000B4417 Steering head removal After having removed the two fixing screws (1) of the steering shock absorber on the frame, loosen the three fixing screws (2) of the steering head.
  • Page 287 Suspension and wheels Then remove the steering head complete with shock absorber and ignition key switch. Protect the steering head with padded material and rest it over the dashboard. Steering base removal - Preliminary operations - Disconnect the connectors (1) of the acoustic war- ning signal;...
  • Page 288 Steering base removal (F4 S - F4 FT - F4 RR) Using the specific tool, loosen the ring nut of the stee- ring spindle, supporting the base of the steering head with a hand.
  • Page 289 Suspension and wheels Remove the anti-dust seal, the internal bearing ring and the ball bearing ring. Steering base removal (F4 R - F4 MY13) Using the specific tool, loosen the ring nut of the stee- ring spindle, supporting the base of the steering head with a hand.
  • Page 290 Suspension and wheels Disassembly of the lower steering bearing 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. Remove the internal bearing ting and the ball bearing ring from the pin of the steering base previously remo- ved from the bike.
  • Page 291 Suspension and wheels Disassembly of the steering sleeve (F4 S - F4 FT - F4 RR) By using the special tool, remove the steering sleeve fixing screw ring. Special tool No. 800092857 Attention: During this operation press the centre of the tool with the palm of the hand.
  • Page 292 Grease only the first threads. Torque pressure: 18 ÷ 20 N·m Screw ring assembly (F4 S - F4 FT - F4 RR) After having accurately cleaned the screw ring and the seats of the steering head on the frame, grease the screw ring and screw it in manually onto the relative seat.
  • Page 293 Suspension and wheels Utilising the special tool, tighten the screw ring (1) to the prescribed torque pressure. 120÷125 N•m Special tool No. 800092857 Torque pressure: 120 ÷ 125 N·m During this tightening operation, press down with force onto the head of the special tool. Assembly of the lower steering bearing If it is necessary to replace the steering base comple- te with pin, before assembling it on the bike you must...
  • Page 294 Suspension and wheels Steering base assembly (F4 S - F4 FT - F4 RR) Fit the steering base to the steering sleeve. Fit the upper ball bearing ring after greasing it. Fit the bearing inner ring, the dust seal and the upper screw ring.
  • Page 295 Suspension and wheels Steering pin tightening (F4 R - F4 MY13) Screw down, without tightening, the screw ring of the steering pin. This operation must be done manually. Ensure that the steering base is turned as far as pos- sible to the right. Utilising the special tool, tighten the screw ring (1) by rotating it 10°...
  • Page 296 Suspension and wheels Extract the ignition block connector (2) from the faste- ning plate and disconnect it. Remove the wiring from the left part of the motorcycle. Remove the complete steering head from the motorcy- cle. - 40 -...
  • Page 297 Suspension and wheels Remove the 2 key switch fixing screws and extract them. When reassembling, apply the following tightening torque: 22 ÷ 24 N·m Steering damper connecting rod removal Remove the locknut of the screw (1) that connects the connecting rod to the steering head. Remove the screw (2) that connects the connecting rod to the steering head.
  • Page 298 Suspension and wheels Connecting rod reassembly Be careful to correctly position washers when reas- sembling. Apply the prescribed thread-locking fluid on the screw (1) that fixes the connecting rod to the steering head. Tighten the screw (1) to the prescribed torque pres- sure.
  • Page 299 10 clicks 10 clicks 10 clicks Steering damper adjustment (F4 S - F4 FT - F4 RR MY12 - F4 R - F4 MY13) The standard adjustment is obtained by fully rotating the knob counterclockwise. In this position the damper...

  • Page 300: Rear Suspension And Swingarm

    45 ÷ 50 70 ÷ 75 Torque Kg· m pressure ft· lb Operation Description F4 S F4 Frecce Tricolori F4 R MY12 F4 MY13 REAR SUSPENSION Type Progressive, single shock absorber with rebound-compression (High speed / Low speed) damping and spring preload adjustment...
  • Page 301 Suspension and wheels Rear shock absorber disassembly Remove the seats, side panels, tank and rear panels as described in Chapter C "Fairings". Lift up the rear part of the motorcycle (with the specific lifter) high enough to take the load off the shock absorber.
  • Page 302 Suspension and wheels Remove the previously loosened upper screw. Remove nut (3) from the central rocker pin. Remove the pin (4) of the compensator assembly (5). - 46 -...
  • Page 303 Check the length of the rear shock absorber spring. Standard spring adjustment (A): - F4 S - FT - F4 R MY12 - F4 MY13: A = 170,5 mm - F4 R MY13 - F4 RR: A = 161 mm Check the functioning of the adjusters.
  • Page 304 Suspension and wheels Rear suspension adjustment (F4 S - FT - F4 R MY12 - F4 MY13) Compression damping hydraulic device (high speed) For rear suspension adjustment, refer to the values shown in the table below. Compression damping hydraulic device (low speed)
  • Page 305 Rebound damping 15 clicks 13 clicks 18 clicks (*): To use the vehicle in this configura- NOTE tion, MV Agusta suggests to increase the rear suspension spring preload of 1 mm (see page 85 of this chapter). - 49 -...
  • Page 306 Suspension and wheels Rocker arm assembly removal Remove the special screw (1) that fixes the compen- sator assembly of the rear suspension to the mono- arm fork. Extract the complete compensator assembly. Rocker arm assembly overhaul Remove the anti-dust seal (1). Check the condition of the roller bearings and if it is necessary to substitute them, utilise an extractor as shown in the figure.
  • Page 307 Suspension and wheels Rear shock absorber support plate removal Remove the three screw (1) indicated in the figure and remove the support plate (2). When reassembling, it is necessary to apply special product to the three screws and lightly screw them in. Tighten the central screw first and then the other two to the prescribed torque pressure.
  • Page 308 Suspension and wheels After having cleaned and greased the seat of the spe- cial screw situated on the mono-arm fork. Screw in the screw without tightening it. Recommended grease: Agip Grease 30 Rear shock absorber assembly Accurately clean all parts. Grease the screws with Agip Grease 30 before reassembly.
  • Page 309 Suspension and wheels SWINGARM REMOVAL AND OVERHAUL Remove the shock absorber and the con-rod of the rear suspension as described in the previous pages. Rear wheel removal Remove the rubber and the safety spring clip (1) and unscrew the screw ring of the wheel. Attention! The screw ring has a left-handed thread.
  • Page 310 Suspension and wheels Lower chain guard removal Remove the three socket head screws (1) of the lower chain guard. Remove the lower chain guard, taking care to recover the internal bushes. Exhaust protection removal Remove the three screws (1) that fix the protection onto the exhaust group.
  • Page 311 Suspension and wheels Extract the wiring and disconnect the three rear head- light connectors. Remove the fixing screw (1) of the exhaust valve plate. Loosen the lock nuts (2) of the valve opening and clo- sing adjusters. - 55 -...
  • Page 312 Suspension and wheels Remove the valve safety plate (1). Disconnect the valve opening and closing adjuster cables. Loosen the screws (2) from the exhaust connection clamp. - 56 -...
  • Page 313 Suspension and wheels To facilitate silencer dismantling operations, remove the rear fixing screw from the central protection. Move the rear end outward. Supporting the silencer unit in its rear part, remove the two exhaust support side screws (1) (see figure). Lower the rear part of the silencer unit by removing the heat guard wiring.
  • Page 314 Suspension and wheels Remove the silencer unit from the exhausts. Upper chain guard removal Remove the screw complete with ferrule. 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 315 Suspension and wheels Unscrew shoulder bolt (2) until you can insert the chain into the special tool. Position the chain breaker (1) so that the ends of the chain pin can fit into the holes of the hex nut and bolt (2). Thread with the fingers the shoulder bolt (2) to put in phase the chain with the tool.
  • Page 316 Suspension and wheels Check that the fork of the new connecting link fork has an O-Ring installed on each pin. Insert the new connecting link fork from the wheel side, avoiding any contact with the pins in order not to remo- ve the lubricant.
  • Page 317 Suspension and wheels PIN RIVETING (Regina 525 ZRPK) Use the professional rivet tool. Special tool no. 8000B1457. Pull the plate (4) to open the positioning rods (3), insert the chain into the tool in correspondance of the first pin to rivet an release the plate (4). The chain should be correctly inserted into the tool and kept in place by rods (3).
  • Page 318 Suspension and wheels CHAIN REMOVAL (D.I.D. 525 HV2) Remove the chain utilising the special tool. Special tool N. 800095389. Identify the connecting link. The part of the tool being indicated must operate on the internal part of the crown wheel. The tool has three functions: NOTE •...
  • Page 319 Suspension and wheels CHAIN REASSEMBLING (D.I.D. 525 HV2) Before reassembling the chain, grease the connecting pins and the O-Rings as shown in the figure, by using the special grease supplied with the chain kit. Utilise only new links. Connect both ends of the chain with the connecting link, and press the connecting plate into the connecting pins by hand.
  • Page 320 Suspension and wheels Mount the tool onto the chain as shown in the figure and align the punch on «A». 30÷35 N•m Turn the pin holder by hand until the plate holder con- tacts with the connecting link plate. Tighten at the specified torque. Connecting link plate press fitting torque pressure: 30 ÷...
  • Page 321 Suspension and wheels Removing the rear brake caliper Loosen the two screws (1) and remove brake caliper (2). Speed sensor cable disassembly Remove the speed sensor cable holding clamp (3). Disconnect the speed sensor cable connector. - 65 -...
  • Page 322 Suspension and wheels Swingarm axle removal Before removing the swingarm axle, loosen the sus- pension rocker pin and the two engine pins. Remove the screw (1) on the left side of the vehicle. Remove the washer and push out the axle manually. Support the swingarm so that it does not drop to the ground.
  • Page 323 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 324 Suspension and wheels Fitting the bearings and the roller cases on the rear swingarm. Take two new roller cases (Part No. 800084936) and two new ball bearings (Part No. 800084938). Preassemble the 2 roller cases (Part No. 800084936) on specific tool Part No. 800092866 (see figure). Fit the assembly to the left side of the swingarm.

  • Page 325: Rear Wheel Hub

    REAR WHEEL HUB N· m 30÷35 20÷22 45÷50 200÷220 28÷32 220÷240 140 5÷7 18÷20 Torque Kg· m pressure ft· lb Operation Description F4 S F4 FT F4 MY13 F4 R MY12 F4 R MY13 F4 RR REAR WHEEL Material Forged Forged Forged...
  • Page 326 Suspension and wheels Before checking and overhauling the rear wheel hub assembly it is necessary to carry out the following pre- liminary operations: Place the motorcycle on the rear stand. Special tool no. 800092642 Remove the rear wheel by removing the polygonal nut. Utilise the following tools: •...
  • Page 327 Suspension and wheels Slacken the nut of the flange by rotating it in an anti- clockwise direction as shown in the figure. Utilise the following tools: • Torque wrench • 55 mm polygonal spanner Slacken the fixings (1) of the wheel hub. Remove the screw complete with bushing.
  • Page 328 Suspension and wheels With the special spanner mounted on the extension tube, pull forward the eccentric adjuster and release the chain from the crown wheel. Special tool: Eccentric adjuster spanner N. 800092854 Spanner extension N. 800092855 When adjusting the tension of the chain it is necessary to carry out the motorcycle set up adjustment.
  • Page 329 Suspension and wheels Remove the rubber clamp (1) around the rear brake pipe. 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.
  • Page 330 Suspension and wheels Brake caliper support flange removal Remove the Seeger retaining ring (1), the spacer ring (2), the flange (3) and the spacer ring underneath. Wheel hub disassembly Extract the wheel hub from the left side of the fork. Carefully wash all parts.
  • Page 331 Suspension and wheels Caliper holder pin 30÷35 N•m Unscrew the caliper holder pin only if it is NOTE damaged. When reassembling apply the prescribed type of Loctite and tighten to the prescribed torque pressure. Recommended thread-locking fluid: Loctite Caliper holder pin torque pressure: 30 ÷...
  • Page 332 Suspension and wheels Check the extra-smooth parts of the wheel spindle for wear (A). Utilising a press with an adequate punch for both the removal and assembly of the pins of the wheel drive engagement. When assembling, apply force on the crown of the peg not on the point.
  • Page 333 Suspension and wheels Evaluate the wear condition of the crown wheel. If it is badly worn, effectuate a substitution with a new part proceeding as described. Extract the 5 spring drives (2) from the gear flange sup- port (3) and assess its condition. If the spring drives are worn, replace with new ones.
  • Page 334 Suspension and wheels Remove the 5 nuts (3) to free the crown (1) from the crown flange (2). Replace the crown. Remount the new crown on the crown flange, making sure the pins (4) enter the holes. 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.
  • Page 335 Suspension and wheels To assemble the brake caliper-carrying flange, carry out the following operations: Grease the O-rings and insert them into their respecti- ve seats on the flange. Assemble the rear spacer ring in contact with the hub, then the brake caliper-carrying flange (1), the second spacer ring and the Seeger retaining ring (1).
  • Page 336 Suspension and wheels Reassemble the brake caliper (1) and tighten the fixing screws (2) at the specified torque. 18 N•m Special product: Loctite 243 Torque pressure: 18 N•m Reinsert the rubber clamp (1) around the rear brake pipe. Insert the spacer with neck illustrated in the figure onto the wheel pin.
  • Page 337 Suspension and wheels Tighten the 5 nuts to block the silentblocks as shown 25 N•m in the figure. Tightening torque: 25 N·m Do not apply grease 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.
  • Page 338 Suspension and wheels Tighten the wheel pin fixing nut by rotating it clockwise as shown in the figure, by using the following tools: • Torque wrench • 55 mm polygonal socket wrench Slip flange nut coupling torque: 200-220 Nm Apply grease only on the threaded part Assemble the retaining ri ng (1).
  • Page 339 Suspension and wheels Remove the screw (1) of the clutch control cylinder and the three screws (2) of the pinion wheel cover. Remove the cover being careful to not extract the clut- ch control rod (it must remain inserted in the engine) and be careful to not lose the two centralising bushes indicated in the figure.
  • Page 340 Suspension and wheels Using the specially designed spanner, remove nut (1) and washer (2). Remove the pinion and replace it with a new pinion. For reassembly, insert the pinion to end stroke. Take a new washer, assemble it with the nut and tight- en to the prescribed torque pressure utilising Loctite thread-locking fluid.

  • Page 341: Motorcycle Set-Up Adjustment

    Two persons must carry out this opera- NOTE tion. Check that dimension x1 is equal to: - F4 S / FT / R MY12 / F4 MY13: = 218 mm - F4 RR MY12 / F4 R MY13: = 222 mm...
  • Page 342 Suspension and wheels Using an Allen key, change the centre distance between the two half linkages by turning adjuster (3). Repeat these operations until X is equal to the refer- ence dimension. Manually and firmly tighten the two tightening lock nuts of the half supports until you hit the adjuster bar.
  • Page 343 Calculate static settling using the following formula: 1 – The static settling value should be: - F4 S / FT / R MY12 / F4 MY13: = 23 mm - F4 RR MY12 / F4 R MY13: = 22 mm - F4 RR MY13:...
  • Page 344 Suspension and wheels WHEEL BALANCE CHECK If the tyres are substituted, it is necessary to effectua- te the following operations balancing and checking the wheels. Front wheel balancing Mount the wheel onto an adequate support similar to that shown in the figure, utilising a ground pin of 35 mm diameter.
  • Page 345 Suspension and wheels Insert the polygonal nut of the balancing tool from the opposite side and screw it onto the threaded part of the tool so that the tool can be fixed to the wheel. Mount the wheel onto an adequate support similar to that shown in the figure, utilising the special tool cod.
  • Page 346 Suspension and wheels When effectuating balancing on certain makes of tyres, it is necessary to refer to the yellow mark (1) present on the side of the tyre as shown in the figure. It indicates the lighte- st point of balancing and must be situated close to the tyre valve when the tyre is moun- ted onto the wheel rim.
  • Page 347 Frame SECTION Revision 2 - 1 -...
  • Page 348 STEERING SLEEVE HOUSING CHECK (F4 S - FT - RR) .......

  • Page 349: Battery Cables

    Frame BATTERY CABLES It is a good rule to disconnect the battery cables before removing components from the motorcycle. After having removed the tail unit and the tank as described in chapter C "Superstructures," remove the fixing screws of the seat/tank support on both sides and remove the bracket.
  • Page 350 Frame Remove the battery from its compartment. If the power cables need to be removed, remove the battery, then, as described before, remove the fixing between the grounding wire and the engine. - 4 -...
  • Page 351 Frame SAS VALVE DISASSEMBLY (MY10 -> MY12) This operation is only necessary if the engine should need to be removed from the frame. Disconnect the SAS valve connector (1). Remove the clamps and the tubes from the blade cov- ers. Remove the valve (2), pulling it from the support out- ward from the right side with the aid of a screwdriver.
  • Page 352 Frame Remove the SAS valve support fixing screws (3) and disassemble the support. If the SAS valve tubes must be removed, when reassembling be careful to correctly phase the clamps to prevent interference with their supports (see figure). - 6 -...

  • Page 353: Side Stand Removal

    Frame SIDE STAND REMOVAL If the side stand needs to be replaced, use the follow- ing procedure: Place the motorcycle on the rear stand (special tool). Special tool No. 800092642 Remove the side fairings and the underfairing as described in the chapter "Superstructures." Disconnect the electrical connector of the safety switch.

  • Page 354: Footrest Removal

    Frame FOOTREST REMOVAL Unscrew the two screws (1) of both footrest supports and remove them. EXHAUST SILENCERS DISASSEMBLY Remove the closing wiring cover on the heat guard, levering with a screwdriver. Extract the wiring and disconnect the three rear head- light connectors.
  • Page 355 Frame Remove the fixing screw (1) of the exhaust valve plate. Loosen the lock nuts (2) of the valve opening and clos- ing adjusters. Remove the valve safety plate (1). - 9 -...
  • Page 356 Frame Disconnect the valve opening and closing adjuster cables. Loosen the screws (2) from the exhaust connection clamp. To facilitate silencer dismantling operations, remove the rear fixing screw from the central protection. Move the rear end outward. - 10 -...
  • Page 357 Frame Supporting the silencer unit in its rear part, remove the two exhaust support side screws (1) (see figure). Lower the rear part of the silencer unit by removing the heat guard wiring. Remove the silencer unit from the exhausts. - 11 -...

  • Page 358: Exhaust Tubes Removal

    Frame EXHAUST TUBE REMOVAL NOTE: This operation is not necessary for disas- sembly of the engine or frame. Proceed as descri- bed below for exhaust manifold replacement. Slide off the Lambda probe connector (1) and lift. Remove the central protection by unscrewing the two screws (2).
  • Page 359 Frame Unscrew the two screws (3), one per part, and remove the front protection. Unscrew the two nuts (4) relative to the manifold tube couple. Remove the nuts and fixing flanges (5). - 13 -...
  • Page 360 Frame Unhook the oil radiator from the rear support pin on the engine to then facilitate removing the manifold. Unscrew the rear support screw (6), holding up the manifold centrally. Remove the manifold as indicated in the figure. - 14 -...

  • Page 361: Side Exhaust Protection Disassembly

    Frame Disassemble the ring seals (3) on the head. Apply sufficiently adequate wadding to the exhaust ports to stop the entry of dirt and dust into the cylin- ders. If the engine has to be removed from the frame, it will be necessary to remove the chain as described in chapter F “Suspension and wheels”.

  • Page 362: Frame Removal Preliminary Operations

    Frame FRAME REMOVAL PRELIMINARY OPERATIONS Support the motorcycle with the aid of the following kickstands: - Code 800092642: Rear kickstand - Code 800095807: Front kickstand - Code 8000B4303: Engine support Remove the following components in order: - Front mudguard - Front brake callipers - Front wheel - Central air manifold as described in chapters F - "Suspension and Wheels"...

  • Page 363: Throttle Body Removal (My10 -> My12)

    Frame THROTTLE BODY REMOVAL (MY10 -> MY12) Remove the electrical connectors on the injectors (1) and on the potentiometer (2). Remove the phase sensor fixing screw (3). Remove the frame vacuum gauge sockets (4) on both sides of the vehicle and recover with adhesive tape. - 17 -...
  • Page 364 Frame Loosen to end stroke the screws (5) of the two pairs of clamps on the suction manifolds as shown in the figure. Loosen the upper throttle control cable fixing nut (6). Disconnect upper cable from the support. - 18 -...
  • Page 365 Frame Loosen the lower throttle control cable fixing lock nut (7). Remove the complete throttle body unit. Fully loosen the lower throttle control fixing nut and remove from the throttle body. - 19 -...
  • Page 366 Frame Remove the clamp from the left suction manifold, move the phase sensor cable and the potentiometer cable to the side and fasten them to the frame with adhesive tape. Protect suction ducts with adhesive tape to prevent dirt intrusion inside the cylinders. Fully tighten the lower throttle control fixing nut when reassembling the throttle body.

  • Page 367: Throttle Body Removal (My13)

    Frame Check the proper passage of the connectors and tube as shown in the figure. Remove the following components in order: - Steering head - Acoustic warning signal - Right/left handlebars - Right/left front forks - Steering sleeve as described in chapter F - "Suspension and Wheels." THROTTLE BODY REMOVAL (MY13) Remove the 2 electrical connectors (1) and (2) of the throttle body.
  • Page 368 Frame Remove the frame vacuum gauge sockets (4) on both sides of the vehicle and recover with adhesive tape. Loosen to end stroke the screws (5) of the two pairs of clamps on the suction manifolds as shown in the figure. Remove the complete throttle body unit.

  • Page 369: Plug-Top Coil Disassembly (My10 -> My12)

    Frame Protect suction ducts with adhesive tape to prevent dirt intrusion inside the cylinders. Remove the following components in order: - Steering head - Acoustic warning signal - Right/left handlebars - Right/left front forks - Steering sleeve as described in chapter F - "Suspension and Wheels." PLUG-TOP COIL DISASSEMBLY (MY10 ->...
  • Page 370 Frame Remove the coil fixing bracket screws. Unhook the injection control unit and disconnect the coil cable connectors. Remove the coils pulling them upward. - 24 -...

  • Page 371: Plug-Top Coil Disassembly (My13)

    Frame Turn coils on the outer side of the motorcycle before removing them. PLUG-TOP COIL DISASSEMBLY (MY13) Remove the 4 male connectors of the coils by sliding the safety lock and pushing the catch as shown in the picture. Remove the 4 female connectors with the help of a screwdriver.
  • Page 372 Frame Remove the coil fixing screws. Remove the coils pulling them upward. Turn coils on the outer side of the motorcycle before removing them. - 26 -...
  • Page 373 Frame Connectors disassembling Disconnect the two exhaust valve control cables from the actuator and remove them from the lower right part. Remove the two control unit fixing screws, sliding them toward the rear part and resting them on the engine. Wind the positive and negative electrical battery cables and position them on the engine.
  • Page 374 Frame Remove the engine rev sensor wiring clamp and dis- connect the connector. Remove the three Lambda probe wiring clamps. Disconnect the Lambda probe connector. Remove the Lambda probe wiring from the upper side of the motorcycle. - 28 -...
  • Page 375 Frame Disconnect the speed sensor and the rear stop con- nector. Disconnect the water temperature sensor connector. Disconnect the alternator connector. - 29 -...
  • Page 376 Frame Disconnect the gear sensor connector. Disconnect side stand switch connector. Disconnect the oil pressure sensor connector. - 30 -...
  • Page 377 Frame Slip the wiring of the two connectors that you just dis- connected behind the water pump tube and wind them on the frame hook present on the left side of the motor- cycle. Unscrew the two battery holder fixing screws on the right side of the motorcycle.
  • Page 378 Frame Disconnect the rear headlight connector. Disconnect the start-up remote switch. Slightly lower the battery holder from the right side and remove the rear frame electrical wiring. - 32 -...

  • Page 379: Frame Disassembly

    Frame Wind the wiring and fasten it on the control unit fixing clamp. FRAME DISASSEMBLY Unscrew and remove the right lower rear fixing nut from the frame. Remove the spindle from the left side of the frame. Unscrew and remove the upper rear fixing screws from both sides of the frame.
  • Page 380 Frame Unscrew and remove the engine fixing screw from the left side of the frame. Loosen the engine fixing screw from the right side of the frame without removing it. Remove the bushes from the rear right and left frame fixing points with the aid of a special tool.

  • Page 381: Frame Checks And Inspection

    Remove the frame from the engine, taking care not to damage the electrical wiring. FRAME CHECKS AND INSPECTION - F4 S - FT - RR: Carefully clean the coupling bevel housing of the steer- ing sleeve. Check that no surfaces have any bumps or dents.
  • Page 382 Frame - F4 R - F4 MY13: Carefully clean the seats of the steering bearings. Check that no surfaces have any bumps or dents. Check that none of the area highlighted in the figure is deformed (as a result of any accidents). Check that there are no dents or evident breakage on frame tubes.

  • Page 383: Frame Control Reference Measurements (F4 S - Ft - Rr)

    Frame FRAME CONTROL REFERENCE MEASUREMENTS (F4 S - FT - RR) 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. - 37 -...

  • Page 384: Frame Control Reference Measurements (F4 R - F4 My13)

    Frame FRAME CONTROL REFERENCE MEASUREMENTS (F4 R - F4 MY13) 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. - 38 -...

  • Page 385: Steering Sleeve Housing Check (F4 S - Ft - Rr)

    Frame Steering sleeve housing check (F4 S - FT - RR) Check the diameter and for any ovalisation on the steering sleeve bevel housing, at 3 mm from the upper and lower edge as shown in the drawing here to the side.

  • Page 386: Steering Bearings Housing Check (F4 R - F4 My13)

    Frame Steering bearings housing check (F4 R - F4 MY13) Check the diameter and for any ovalisation on the steering bearings housing as shown in the drawing here to the side. Measure ovalisation in different points as shown in the diagram.

  • Page 387: Frame Assembly On The Vehicle

    These components can be assembled on the new frame after having carried out a careful inspection. Contact MV AGUSTA spare parts service for approval punching and decals on the new frame. Carefully clean the frame-engine head and frame- rear suspension plates coupling planes.
  • Page 388 Frame Before proceeding with frame reassembly, replace the previously removed electrical wiring and components. See Chapt. E - Electrical System regarding the posi- tioning and passage of cables, clamps and wiring. - 42 -...

  • Page 389: Preliminary Wiring Positioning Operations On The Engine

    Frame Preliminary wiring positioning operations on the engine (F4 S - FT - RR) To facilitate reassembly, before repositioning the frame on the vehicle, perform the following cable and tubing positioning checks. - Make sure that alternator and gear sensor connectors are in position (A).
  • Page 390 Frame Carry out the sequence of operations of assembly in reverse order to removal for the correct assembly of the frame to the motorcycle. Tighten the various fixings to the torque pressure shown in the following diagram. PART. DESIGN NO. DESCRIPTION DIM.
  • Page 391 Frame - 45 -...

  • Page 392: Rear Frame Disassembly

    Frame REAR FRAME DISASSEMBLY Remove the rubber caps from the upper fixing screws on the rear frame. Remove the four frame fixing screws. Hold the frame up before removing the last screw. Remove the rear frame from the vehicle. - 46 -...

  • Page 393: Frame Plate Removal

    Frame FRAME PLATE REMOVAL Cut the chain as described in chapter F "Suspension and Wheels." Remove the exhaust manifold support screw from the right side of the motorcycle. Disconnect the rear brake pump connector. Remove the rear brake pump fixing screws. - 47 -...
  • Page 394 Frame Remove the rear brake pump and wind it with protec- tive material. Remove the gear control pedal. Remove the rear wheel fixing nut and disassemble the wheel. - 48 -...
  • Page 395 Frame Position an adequate support under the rear part of the motorcycle. Loosen the fork spindle pivot nut from the right side of the motorcycle. Partially slide the fork spindle pivot off from the left side of the motorcycle. - 49 -...
  • Page 396 Frame Remove the plate-rear suspension unit from the engine, moving it from the rear part of the motorcycle. Remove the rear brake fluid tank. Remove the rocker spindle fixing nut. - 50 -...
  • Page 397 Frame Remove the fork pivot spindle fixing nut. Remove the rocker spindle from the left side of the motorcycle. Remove the right frame plate. - 51 -...

  • Page 398: Rear Frame Unit Assembly

    Frame Remove the fork pivot spindle from the left side of the motorcycle. Remove the left frame plate. REAR FRAME UNIT ASSEMBLY To assemble the rear sub-frame unit to the motorcycle, proceed in the reverse order of removal. Tighten the four fixing screws (1), two on each side, to the pre- scribed torque pressure.

  • Page 399: Engine Disassembly From The Frame

    Frame ENGINE DISASSEMBLY FROM THE FRAME Support the motorcycle with the aid of the following kickstands: - Code 800092642: Rear kickstand - Code 800095807: Front kickstand - Code 8000B4303: Engine support Remove the following components in order: - Throttle body (page 17) - Secondary air valve (page 5) - Water radiator (chapt.
  • Page 400 Frame Disconnect the two exhaust valve control cables from the actuator and remove them from the lower right part. - Only for F4 MY10 -> MY12: Remove the two control unit fixing screws, sliding them toward the rear part and resting them on the engine. Disconnect the coil cable connectors and remove them as shown in the figure.
  • Page 401 Frame - Only for F4 MY10 -> MY12: Temporarily reposition the control unit on the frame, partially screwing in one screw. Remove the previously removed battery cable clamp and wind the cables themselves on the engine. Remove the wiring holding clamp on the right side and disconnect the rev sensor connector.
  • Page 402 Frame Disconnect the Lambda probe connector. Disconnect the complete rear brake pump, removing the two screws. Insert the rear brake pump in a protection cap, fixing it with an elastic on the frame. - 56 -...
  • Page 403 Frame Remove the screw and remove the gear pedal. Remove the four clutch cover fixing screws. Remove the cover holding the clutch control rod on the engine. - 57 -...
  • Page 404 Frame Protect the cover with a nylon cap and remove the two wiring holding clamps. Rest the cover on the handlebar. Break the chain as described in chapt. F "Suspension and Wheels" and remove the chain from the pinion. - 58 -...
  • Page 405 Frame Disconnect the kickstand connector and the oil pres- sure connector. Move wiring upward, winding it on the frame. Disconnect the gear sensor connector and the alterna- tor cable connector. - 59 -...
  • Page 406 Frame Disconnect the water temperature sensor connector. Loosen the fork spindle tightening screw, turning it once. Loosen the rocker spindle nut from the rear suspen- sion. - 60 -...
  • Page 407 Frame Remove the lower engine spindle nut. Extract the lower engine fixing spindle from the left side of the motorcycle. Remove the upper engine spindle nut. - 61 -...
  • Page 408 Frame Extract the upper engine fixing spindle from the left side of the motorcycle. Remove the front engine support screws (one per side). With a special tool, extract the bushes (one per side) of approximately 15 cm in order to free the engine. Special tool No.
  • Page 409 Frame Push the engine forward by hand approximately 3 cm. Lower the rear engine support screw in order to turn the engine downward. Lift the front part of the motorcycle by means of the rel- ative front kickstand crank. - 63 -...

  • Page 410: Engine Assembly On The Frame

    Use the crank to free the engine. ENGINE ASSEMBLY ON THE FRAME Preliminary wiring positioning operations on the engine (F4 S - FT - RR) To facilitate reassembly, before repositioning the engine on the vehicle, perform the following cable and tubing positioning checks.
  • Page 411 Frame Reposition the engine under the motorcycle. Lower the front part of the motorcycle by means of the relative front kickstand crank. Use the crank to align it for front engine fastening. This operation must be performed several times in order to prevent damage to the frame with the head- cylinder fixing screw.
  • Page 412 Frame Fully lower the front kickstand. Lift the rear engine support screw in order to turn the engine upward and realign with fixing holes. Insert the lower engine fixing spindle. - 66 -...
  • Page 413 Frame Rest the two front support screws (one per part). With a special tool, bring the engine centring bushes in position. Insert the upper engine support spindle. Make sure the wiring on the right side follows the direc- tion of the frame tubes. Perform all other remaining operations in the reverse order of disassembly, lubricating the various fasteners and tightening them to the torques detailed on page...
  • Page 414 Frame - 68 -...
  • Page 415 Brakes SECTION Revision 2 - 1 -...
  • Page 416 FRONT BRAKE PUMP REMOVAL (F4 S - F4 FT - F4 R - F4 MY13) ......PAGE...

  • Page 417: Front Brake System

    40 ÷ 42 23 ÷ 26 16 ÷ 18 8 ÷ 10 23 ÷ 25 Torque Kg·m pressure ft·lb Operation Description F4 S F4 Frecce Tricolori F4 MY13 F4 R F4 RR FRONT BRAKE Type Dual floating disc with steel braking band Ø...

  • Page 418: Front Brake Pads Substitution

    Brakes FRONT BRAKE PADS SUBSTITUTION To replace the front brake pads, remove the front brake caliper, as detailed in the “Suspensions and Wheels” section. Widen the pads with a screwdriver so that the pistons are pushed back into their seats (as shown in the fig- ure).
  • Page 419 Brakes Before fitting the pads back in, make sure the plate rests against its stop. If it does not, push it down, as shown in the Figure. Fit either pad through the midst of the front back caliper opening, then push it towards its pistons. Do the same with the other pad.

  • Page 420: Substitution And Bleeding Of The Front Brake Fluid

    Brakes SUBSTITUTION AND BLEEDING OF THE FRONT BRAKE FLUID (F4 S - F4 FT - F4 R - F4 MY13) Place the motorcycle on a horizontal surface with the steering in a straight line. It is advisable to remove the nose fairing when carry- ing out this operation.
  • Page 421 Brakes Fill the system by pulling the front brake lever 3-4 times (see figure). Repeat the above operations until the fluid reaches the minimum level in the reservoir. Top up with fresh fluid and carry on with the operation until fluid of a different colour (fresh) flows out.
  • Page 422 Brakes Pour new brake fluid into the chamber until it reaches the maximum level. Recommended brake fluid: AGIP Brake 4 Utilise only the prescribed brake fluid from sealed containers. NEVER use old or used brake fluid. Top-up the level of the fluid until it reaches the maxi- mum mark.
  • Page 423 Brakes Accurately clean the three elements of the brake fluid chamber cap with alcohol and dry with compressed air. Place the cap on the brake fluid tank and tighten the two lateral fixing screws. - 9 -...

  • Page 424: Substitution And Bleeding Of The Front Brake Fluid (F4 Rr)

    Brakes SUBSTITUTION AND BLEEDING OF THE FRONT BRAKE FLUID (F4 RR) Place the motorcycle on a horizontal surface with the steering in a straight line. It is advisable to remove the nose fairing when carry- ing out this operation. Remove the two screws of the front brake fluid cham- ber cover.
  • Page 425 Brakes Fill the system by pulling the front brake lever 3-4 times (see figure). Repeat the above operations until the fluid reaches the minimum level in the reservoir. Top up with fresh fluid and carry on with the operation until fluid of a different colour (fresh) flows out.
  • Page 426 Brakes 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. Air bubbles should not rise in the chamber. If the bleeding has been done correctly, the movement of the lever is short and without any elastic effect.
  • Page 427 Brakes 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. Accurately clean the elements of the brake fluid cham- ber cap with alcohol and dry with compressed air.

  • Page 428: Front Brake Calipers Substitution

    Torque pressure calipers screws: 40 42 N FRONT BRAKE PUMP REMOVAL (F4 S - F4 FT - F4 R - F4 MY13) Remove the cap from the front brake fluid reservoir and drain the reservoir with a syringe. Remove the union shown in the figure.

  • Page 429: Front Brake Pump Removal (F4 Rr)

    Brakes Remove the connectors of the electrical system. Remove the fixing screw that fixes the pump to the handlebar. Open the clamp. Push down to remove the pump from the reference pin. When reassembling the pump, fix and tighten the fixing screw at the prescribed torque.
  • Page 430 When reassembling the pump, fix and tighten the fixing screws at the prescribed torque. Torque pressure: 7÷9 Nm REPLACING THE BRAKE FLUID RESERVOIR (F4 S - F4 FT - F4 R - F4 MY13) Loosen fixing screw (1) and then remove the brake fluid reservoir. - 16 -...
  • Page 431 Brakes Thoroughly clean housing (1). Fit O-ring (2) into its groove. Use a new O-ring. NOTE Place reservoir (1) in its housing (2). Insert rubber separator (3). Put a thread-brake of the recommended type on the first few threads of the locking screw (1). Specific product: Loctite 243 Insert the fixing screw (1) into the corresponding threaded hole and tighten the screw to the prescribed...

  • Page 432: Replacing The Front Brake Switch (F4 S - F4 Ft - F4 R - F4 My13)

    Remove the brake fluid reservoir. REPLACING THE FRONT BRAKE SWITCH (F4 S - F4 FT - F4 R - F4 MY13) To replace the front brake switch, remove the screw shown in the figure. After having carried out the overhaul of the...

  • Page 433: Replacing The Front Brake Switch (F4 Rr)

    To remove the clutch switch, follow the NOTE procedure used for the front brake switch. CLUTCH/FRONT BRAKE LEVER REMOVAL (F4 S - F4 FT - F4 R - F4 MY13) Remove the nut shown in the figure. Unscrew the pin. Remove the clutch lever.

  • Page 434: Clutch/Front Brake Lever Removal (F4 Rr)

    Brakes When reassembling, be careful to insert the pin of the pump piston into the seat situated on the lever (see figure). Grease the pin: Recommended grease: Agip Grease 30 For the reassembly of the lever tighten the pin. Tighten the nut while holding the pin in place with a flat blade screwdriver.

  • Page 435: Front Brake Discs

    Brakes Extract the pin. Remove the front brake lever. For the reassembly of the lever, grease the pin with the prescribed product. Recommended grease: Agip Grease 30 Screw and tighten the pin. Tighten the nut while holding the pin in place. Torque pressure: 5 ÷...

  • Page 436: Front Brake Disc Removal

    Brakes FRONT BRAKE DISC REMOVAL Take down the front wheel as described in chapter F "Suspensions and Wheels". Using two special spanners (see chapter F "Suspen- sions and Wheels"), remove the front wheel spindle. Special tool 800092872 Place the wheel in a horizontal position and remove the five screws of each disc proceeding in a star-like mode for the removal.

  • Page 437: Front Brake Disc Assembly

    Brakes FRONT BRAKE DISC ASSEMBLY Thoroughly clean the contact surfaces of the discs and the wheel. Accurately grease all relative surfaces of the disc before reassembling. The following operation is to be carried out on all mod- els. Apply thread-locking fluid to the five fixing screws of the disc.

  • Page 438: Rear Brake System

    16 ÷ 18 8 ÷ 10 18 ÷ 20 16 ÷ 18 Torque Kg·m pressure ft·lb Operation Description F4 S F4 Frecce Tricolori F4 MY13 F4 R F4 RR REAR BRAKE Type Single steel disc Ø disc (mm) Caliper (Ø pistons mm) With 4 pistons (Ø...

  • Page 439: Rear Brake Pads Substitution

    Brakes REAR BRAKE PADS SUBSTITUTION Remove the safety retainer and unscrew the rear ring nut by turning it clockwise (see figure). Remove the wheel. Utilising circlip pincers as shown in the figure, widen the pads so that the pistons are pushed back into their seats.
  • Page 440 Brakes Remove the pad support pin (1) and the relative spring (2). Remove the pad (3) by letting it drop down. Carry out the check every 6000 kilometres. Brake disc Brake pads Check the condition of the rear braking system and its components.

  • Page 441: Substitution And Bleeding Of The Rear Brake Fluid

    Brakes Tighten the pin to the prescribed torque pressure. 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 because of the nearness of the exhaust tubes that could cause grave burns.
  • Page 442 Brakes Connect a rubber tube to the bleed valve, empty the system in an appropriate container by slackening the bleed valve as shown in the figure Tighten the bleed valve. Fill the rear brake fluid reservoir until the fluid reaches the maximum level.

  • Page 443: Rear Brake Calipers Substitution

    Brakes REAR BRAKE CALIPER SUBSTITUTION To facilitate the operation, remove the brake pads as described previously. Empty the rear brake system as previously described in the paragraph “SUBSTITUTION AND BLEEDING OF THE REAR BRAKE FLUID”. Remove the tubing by unscrewing the union indicated in the figure.
  • Page 444 Brakes Rear brake pump removal Carry out the emptying of the brake system as previ- ously described. Remove the clip with the pump control fork pin by turn- ing the pin and pulling it out (see figure). Unscrew connection (1) as shown in the figure so as to disengage the pump from the brake line.

  • Page 445: 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 with the assembly by following the procedure in reverse order of removal. Substitute the gaskets of the pump/caliper NOTE hoses. Tighten the fixings to the prescribed torque pressure.

  • Page 446: Rear Brake Disc Assembly

    Brakes Check the planarity of the rear brake disc by utilising a micrometer gauge and placing the disc on a level work surface. Utilise the same procedure adopted for the front wheel discs. The planarity value must not exceed 0.3 mm. Utilise a micrometer gauge with support to carry out this check.
  • Page 447 Cooling system SECTION Revision 0 - 1 -...

  • Page 448: Cooling System

    Cooling system SUMMARY COMPLETE COOLING SYSTEM ASSEMBLY ..........PAGE 3 COOLING SYSTEM LEAKAGE CHECK .

  • Page 449: Complete Cooling System Assembly

    Cooling system COMPLETE COOLING SYSTEM ASSEMBLY Before proceeding with the disposal or overhaul of any component relative to the cooling system, carry out cer- tain preliminary operations: 1) Let the engine cool down. 2) Remove the side fairings, the underfairing, the fairings push rod, the headlight fairing, the suction duct covers and suction ducts as described in the chapter "Superstructures."...

  • Page 450: Cooling System Leakage Check

    Cooling system COOLING SYSTEM LEAKAGE CHECK Before removing the radiator and discharging the engine coolant, check that the cooling system does not have leakages. Remove the water radiator cap and connect the tester (of the type shown in the diagram) to the filler hole. Do not open the radiator cap whilst the engine is hot.

  • Page 451: Engine Coolant Extraction

    Cooling system ENGINE COOLANT EXTRACTION Remove the water radiator cap. Open the cap of the expansion tank. Empty the cooling system of the coolant as follows: • Place under the engine a container to collect the dis- charged coolant. • Remove the discharge screw (1) situated on the water pump (2) •...
  • Page 452 Cooling system Disconnect the tension regulator connector from the left side of the motorcycle and remove the holding clamp. Disconnect the three clic holding clamps of the radiator tubes. Special tool: CLIC 205 pincers Disconnect the tubes. - 6 -...
  • Page 453 Cooling system Remove the upper and lower fixing screws of the radia- tor from the left side. Special tool: CLIC 205 pincers Remove the upper central radiator fixing screw. Holding the upper radiator (water), push the lower radiator (oil) toward the right to remove the connector pin.
  • Page 454 Cooling system Lower the left side radiator and push it toward the right to remove the upper support pin. Extract the radiator from the left side, turning it as shown in the figure. If necessary, to carry out overhauling of the lower water union tube, remove the two clic clamps at the end of the radiator filling tube on the left side of the motorcycle.
  • Page 455 Cooling system Remove the tube. Before carrying out this operation, position a collection container under the engine to collect any residual liquid. Carry out the said operations with care. NOTE Pour the remaining coolant inside the radiator into an appropriate container. Do not dispose of engine coolant in the envi- ronment.

  • Page 456: Water Radiator Component Disassembly

    Cooling system WATER RADIATOR COMPONENT DISASSEMBLY Expansion tank removal Unscrew the expansion tank cap. Empty the tank in an appropriate container. Disconnect the clic holding clamp of the water radiator recovery tube and remove the tube. Special tool: CLIC 205 pincers - 10 -...
  • Page 457 Cooling system Remove the two radiator tray screws and remove the tray itself. Check for any tube faults. Tension regulator disassembly Remove the two tension regulator support fixing screws and remove the regulator. Electric fan disassembly Remove the central cable holding clamp. - 11 -...
  • Page 458 Cooling system Remove the two rigid clamps cutting them with clip- pers. Disconnect the two electric fan cable connectors. Remove the 6 fan rack fixing screws (3 per side) and remove racks. - 12 -...
  • Page 459 Cooling system Radiator fastening component disassembly. Remove the four threaded clips. Release the closing cap clic clamp and remove everything. Special tool: CLIC 205 pincers - 13 -...
  • Page 460 Cooling system Unscrew and remove the radiator anchoring pin. Remove the left upper support bracket spacer. Remove the upper support bracket vibration dampers. - 14 -...
  • Page 461 Cooling system RADIATOR GROUP ASSEMBLY Before reassembling, check the correct rotation of the fans, the condition of all components and all connec- tions. Radiator check and clean The dirt and extraneous material embedded in the radi- ators must be removed. It is recommended to use compressed air for the clean- ing of the radiator.
  • Page 462 Cooling system Tighten the 6 screws (3 per fan) to the prescribed tigh- tening torque. Torque pressure: 5 ÷ 6 N·m Replace the previously removed components following the disassembly procedures inversely. 5÷6 N•m Recovery tank fixing screws: 8 N•m Torque pressure: 8 N·m Recommended threadlocking product: Loctite 243 Radiator connection pin:...
  • Page 463 Cooling system The assembly of the new radiator group has been completed. At the end of the assembly operation, the radiator group should look like the group indicated in the figure. The radiator group can be mounted onto the motorcy- cle.
  • Page 464 Cooling system Check Check to see if the thermostat pad is damaged. Check the functioning of the thermostat as follows: • Suspend the thermostat by a piece of string threaded through the flange as indicated in the figure. • Immerse the thermostat in water contained in a labo- ratory glass as indicated in the figure.
  • Page 465 Cooling system THERMOSTAT ASSEMBLY Insert the O-ring (1) in its appropriate seat on the cover of the thermostat. Check the condition of the O-ring previously utilised. If the O-ring is not in good condition, substi- tute it with a new one. Apply a thin layer of silicone grease.

  • Page 466: Water Radiator Vehicle Unit Assembly

    Cooling system Insert the thermostat cover on the engine. Tighten the three fixing screws (1) to the prescribed torque pressure. Torque pressure: 10 N·m Replace the tubes on the thermostatic valve and fasten the relative clic clamps. 10 N•m WATER RADIATOR VEHICLE UNIT ASSEMBLY Insert the upper right radiator mount into the peg on the frame (right side).

  • Page 467: Oil Radiator Disassembly

    Cooling system OIL RADIATOR DISASSEMBLY Insert the receptacle under the engine and remove the oil drain screw. Proceed with emptying oil present in the engine. Remove the clamps from both sides of the central water tube with the aid of a screwdriver. - 21 -...
  • Page 468 Cooling system Remove the screws from the tube holding plate of the radiator and remove the plate. Remove the lower oil radiator support bracket. Move the tube support plate outward to facilitate the following operations. - 22 -...
  • Page 469 Cooling system Remove the tube unions from the right side of the oil radiator with the aid of a screwdriver. Remove the central water tube from the supports on the oil radiator. Remove the oil radiator support screw from the left side of the motorcycle.
  • Page 470 Cooling system Lower the oil radiator from the left side and push toward the right to free it from the support pin. Remove the oil radiator. Check the conditions of the component and, if neces- sary, straighten the folded flaps with a screwdriver. - 24 -...

  • Page 471: Oil Radiator Assembly

    Cooling system OIL RADIATOR ASSEMBLY Before reassembly, check the integrity of the oil tubes and replace if necessary. Also check conditions of the oil tube union seal rings and replace if necessary. Grease O-rings with silicone grease. Reassemble previously removed components in the opposite order of disassembly.

  • Page 472: Filling The Cooling System

    Cooling system FILLING THE COOLING SYSTEM Lift the front part of the motorcycle as shown in the figure. Fill the cooling system with a suitable liquid described in the table (see page B-8) until you reach the level of the bar of the radiator filler cap. Do this in stages to sta- bilise the liquid level.

  • Page 473: Motor Oil System Filling

    Cooling system MOTOR OIL SYSTEM FILLING Unscrew filler plug using the 10-mm hexagonal bar provided fitted to a specially designed spanner (see figure). Pour in the required quantity of oil. Check the level of oil in the appropriate window. Before replacing the filler plug, grease O-ring (1) with silicone grease, then reinsert it into its seat (see fig- ure).
  • Page 474 Cooling system SYSTEM FUNCTIONING CHECK Assemble the following components in order: • Airbox. • Fuel tank. • Rear side panels. • Fuel tank side panels. • Airbox side panels. For the assembly operations, assemble in reverse order of removal. Cooling system Insert the ignition key and start up the vehicle engine.
  • Page 475 Special tools SECTION Revision 3 - 1 -...
  • Page 476 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 477 Special tools Code Q.ty Note F4 S F4 FT F4 MY13 F4 R F4 RR Descrizione Description 800095830 • • • • • Cavalletto Front stand anteriore 800091645 • • • • • Chiave ghiera Steering bearing cuscinetti di sterzo...
  • Page 478 Special tools - 4 -...
  • Page 479 Special tools Code Q.ty Note F4 S F4 FT F4 MY13 F4 R F4 RR Descrizione Description 800092867 • • • • • Attrezzo montaggio Equaliser pacco bilanciere pack tool 8000B4421 • • • • • Attrezzo cuscinetti Front wheel...
  • Page 480 Special tools - 6 -...
  • Page 481 Special tools Code Q.ty Note F4 S F4 FT F4 MY13 F4 R F4 RR Descrizione Description 8A0094792 • • • • • Attrezzo montaggio Gear change cambio mounting tool 800086119 • • • • • Bussola di Locating bush...
  • Page 482 Special tools - 8 -...
  • Page 483 Special tools Code Q.ty Note F4 S F4 FT F4 MY13 F4 R F4 RR Descrizione Description 8000B4726 • • • • • Distanziale per dado Spacer for speciale special nut 800079015 • • • • • Attrezzo bloccaggio Clutch blocking tool...
  • Page 484 Special tools - 10 -...
  • Page 485 Tightening torques SECTION Revision 3 - 1 -...

  • Page 486: Tightening Torques

    FRAME TIGHTENING TORQUES – F4 S - FT - R MY 2012 ......
  • Page 487 Tightening torques - 3 -...
  • Page 488 Tightening torques - 4 -...
  • Page 489 Tightening torques - 5 -...
  • Page 490 Tightening torques - 6 -...
  • Page 491 Tightening torques - 7 -...
  • Page 492 Tightening torques - 8 -...
  • Page 493 Tightening torques - 9 -...
  • Page 494 Tightening torques - 10 -...
  • Page 495 Diagnostic SECTION Revision 1 - 1 -...

  • Page 496: Electrical Components

    Diagnostic ELECTRICAL COMPONENTS CHARGING SYSTEM Battery warning light on Alternator broken Replace Alternator connection defective Check Voltage regulator connection defective Deoxidize/Repair Voltage regulator broken Replace Battery faulty Replace Recharge fuse (40A) blown Replace Recharge fuse connection defective Deoxidize/Repair Battery connections oxidized Deoxidize/Repair POWER SUPPLY FOR 12V SERVICES No function enabled...
  • Page 497 Diagnostic Brake light does not work MY10->MY12: Fuse 1 blown Replace MY13: Fuse 6 blown Replace MY10->MY12: Fuse 1 connection faulty Deoxidize/Repair MY13: Fuse 6 connection faulty Deoxidize/Repair Device damaged Replace Front brake lever switch broken Replace Front brake lever switch connection faulty Deoxidize/Repair Rear brake lever switch broken Replace...
  • Page 498 Diagnostic Low fuel warning light does not work Fuel level sensor broken Replace Fuel level sensor connection faulty Deoxidize/Repair Instrument panel broken Deoxidize/Repair Instrument panel connection faulty Deoxidize/Repair Indicator warning light does not work Flasher unit broken Replace Flasher unit connection faulty Deoxidize/Repair Instrument panel broken Replace...
  • Page 499 Diagnostic FRAME STEERING Steering stiff Steering bearings damaged Replace Steering bearings overtightened Adjust Steering pin bent Replace Steering damper action excessive Adjust Steering damper joints damaged Replace Tyre pressure low Adjust Vehicle tends to steer or does not travel on a straight line Fork bent Replace Frame bent Replace...
  • Page 500 Diagnostic Swingarm bearings damaged Replace Swingarm rocker bearings damaged Replace Shock absorber joints damaged Replace Suspension linkage joints damaged Repair Swingarm pin bent Replace BRAKES Brake lever and pedal soft (“spongy”) Air bubbles in hydraulic circuit Bleed Leaks in hydraulic circuit Repair Caliper seals damaged Replace...
  • Page 501 Analytical index SECTION Revision 3 - 1 -...
  • Page 502 Analytical index ANALYTICAL INDEX - F4 WORKSHOP MANUAL Throttle body adjustment and calibration (MY13) .......B-41 Section A - General Description Throttle control (MY10->MY12) .
  • Page 503 – Turn indicators check ....E-41 (F4 S - FT - RR) ......G-37 –...
  • Page 504 Frame tightening torques (F4 S - FT - R MY2012) ....N-3-4 (F4 S - F4 FT - F4 R - F4 MY13) ..H-14 Frame tightening torques –...

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