Page 2 © 2007 The reproduction, even partial of this document is forbidden without prior written agreement of MV Agusta Motor S.p.A. Part No. 8A0099360 - Edition No. 4 Printed – July 2007...
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: Table Of Contents
Freni General Index GENERAL DESCRIPTION ..................Rev. 0 MAINTENANCE ......................Rev. 3 BODYWORK ......................Rev. 1 AIR INTAKE INJECTION SYSTEM ................Rev. 1 ELECTRICAL SYSTEM .................... Rev. 2 SUSPENSION AND WHEELS .................. Rev. 3 FRAME ........................Rev. 2 BRAKES ........................Rev.
Page 7: General Description
General description SECTION Revision 0 - 1 -...
Page 8 General description SUMMARY HOW TO CONSULT THIS MANUAL ......................PAGE 3 PURPOSE OF THE MANUAL ........................PAGE 3 GLOSSARY AND SYMBOLS ........................PAGE 4 RIGHT HAND AND LEFT HAND STANDARD ..................PAGE 5 SAFETY ..............................PAGE 6 WARNING ..............................PAGE 8 INDEX................................PAGE 8 OPERATIVE TECHNICAL SPECIFICATIONS ...................PAGE 9 - 2 -...
Page 9: How To Consult This Manual
All information, instructions and technical data included in this manual are based upon information on the product updated at the moment of going to print. MV Agusta S.p.A. reserves the right to carry out changes at any moment without prior notice and without incurring any obligation.
Page 10: Glossary And Symbols
General description GLOSSARY AND SYMBOLS This signifies that the lack of ATTENTION or the incomplete observan- Use the recommended suspension fluid. ce of this advice can be gra- vely dangerous for your safety and for the safety of other persons. This signifies that the lack of Use the recommended coolant.
Page 11: Right Hand And Left Hand Standard
General description RIGHT HAND AND LEFT HAND STANDARD In order to specify the right/left convention used within the chapters of this manual, see the following motorcycle and engine scheme where all sides which refer to are reported. Cylinder 3 Cylinder 2 Cilindro 2 Cilindro 3 Cylinder 4...
Page 12: Safety
• Used oil contains dangerous substances and poisonous for the environment. To substitute oil, it is recommended to go to an authorised MV Agusta dealer who is equipped to deal with the collection of used oil in respect of the norms in force.
Page 13 • The battery contains dangerous substances that are poisonous for the environment. It is advisable to substitute it at an MV Agusta dealer that is equipped to dispose of this product in respect of the norms in force. • Do not dispose of used batteries in the environment.
Page 14: Warning
• Loosening and tightening nuts or screws, always start from the bigger ones or the centre. Always comply with the torque wrench settings. • Utilise only MV Agusta spare parts. INDEX GENERAL INDEX SUMMARY OF EACH CHAPTER...
Page 15: Operative Technical Specifications
General description OPERATIVE TECHNICAL SPECIFICATIONS MOTORCYCLE IDENTIFICATION Frame registration number Engine registration number Homologation date "Limited series" number H The registration number of the motorcycle is stamped on the right side of the steering head. The engine part number is stamped on the top half casing near the fork. 4) numero "serie limitata"...
Page 16 General description - 10 -...
Page 17: Maintenance
Maintenance SECTION Revision 3 - 1 -...
Page 18 TECHNICAL DATA ..............PAGE 3 COMPONENTS IN CARBON FIBRE (F4 BRUTALE 750 ORO) ......PAGE 6 MAGNESIUM COMPONENTS (F4 BRUTALE 750 ORO) .
Page 19: Technical Information
Maintenance TECHNICAL INFORMATION 2020 1410 TECHNICAL DATA Description BRUTALE 750 ORO BRUTALE 750 S BRUTALE 910 S BRUTALE 910 R CHARACTERISTICS Wheelbase (mm) (*) 1410 1410 1410 1410 Total length (mm) (*) 2020 2020 2020 2020 Maximum width (mm) Seat height (mm) (*) Ground clearance (mm) (*) Trail (mm) (*) 101.5...
Page 20 Maintenance TECHNICAL DATA Description BRUTALE 750 ORO BRUTALE 750 S BRUTALE 910 S BRUTALE 910 R TIMING Type D.O.H.C. radial valves LUBRICATION Type Wet sump IGNITION – FUEL FEED SYSTEM Type “Weber-Marelli” integrated ignition-injection system 1.6 M. “Weber-Marelli” integrated ignition-injection system 1.6 M (MY05/06) or 5 SM (MY07). Electronic inductive discharge ignition, “Multipoint”.
Page 21 Maintenance TECHNICAL DATA Description BRUTALE 750 ORO BRUTALE 750 S BRUTALE 910 S BRUTALE 910 S ELECTRICAL SYSTEM Voltage Front dipped beam light bulb 12V 55W 12V 55W 12V 55W 12V 55W Front main beam light bulb 12V 60W 12V 60W 12V 60W 12V 60W Front sidelight bulb...
Page 22: Components In Carbon Fibre (F4 Brutale 750 Oro)
Maintenance # COMPONENTS IN CARBON FIBRE (F4 BRUTALE 750 ORO) - Right air filter compartment side panel - Ignition switch cover - Left air filter compartment side panel - Tail unit - Right tank side panel 10 - Front mudguard...
Page 23: Magnesium Components (F4 Brutale 750 Oro)
Maintenance # MAGNESIUM COMPONENTS (F4 BRUTALE 750 ORO) - Steering base - Frame side plates - Front wheel rim - Rear wheel rim - Swingarm - 7 -...
Page 24: 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 25 Maintenance Programmed maintenance schedule 1000 6000 12000 18000 24000 30000 36000 Km (mi) covered (600) (3800) (7500) (11200) (14900) (18600) (22400) Pre- Service delivery Description Operation ● ● ● ● ● ● ● ● Transmission and flexible controls Check / Adjust ●...
Page 26: Maintenance And Tuning Operations
MOTUL CHAIN LUBE ROAD – * : To find the recommended product, MV Agusta suggests going directly to the authorised MV Agusta dealers. AGIP Racing 4T 10W/60 has been manufactured for the F4 engine. If the described oil is not available, MV...
Page 27 Maintenance To accede to the oil filter and the discharge and filling holes of the engine oil, it is necessary to carry out cer- tain operations beforehand: • Place the motorcycle on the rear stand. The substitution of the engine oil must N.B.
Page 28 Maintenance Unscrew the lower fixing screws of the oil cooler pro- tection on the lower basis of the water radiator. Remove the oil cooler protection. Slightly move the coolers towards the front area of the motorcycle, then unscrew the nut on the fixing flange of the exhaust manifilds of the cylinder group.
Page 29 Maintenance For Brutale 910 S – 910 R (MY2007) models only: Disconnect the lambda probe connector from the main cabling and pull outwards, on the right side of the vehi- cle. Unscrew the compensatory housing fixing screws. Unscrew the pin from the left side of the housing. - 13 -...
Page 30 Maintenance Remove the exhaust manifolds by turning slightly towards the right of the vehicle. In order to facilitate the reassembly of the N.B. manifolds you should place the fixing flange on the manifolds before these manifolds are pleced on the engine. Insert the flange in the manifolds and then turn it.
Page 31 Maintenance Unscrew the oil filter by an appropriate wrench. FACOM D. 139 tool Part code 8000A4317 Clean accurately any oily parts. Using a clean cloth to clean accurately the area and the filter face. Take out the oil filter from the new engine oil filter kit (Part Code No.
Page 32 Maintenance Take a new rubber clamp from the motor’s oil filter kit and place it on the filter as shown in the figure to the left. Only use new parts. Let the rubber clamp slide until it comes into contact with the back ring of the oil filter (see figure to the right).
Page 33 Maintenance Tighten the filter using the appropriate tool and a tor- que wrench. FACOM D. 139 tool Part code 8000A4317 Oil filter torque wrench: 24 N·m 24 N•m After having tightened the filter, take out the clamp for engine oil filter and its screw from the new oil filter kit. Only use a new clamp.
Page 34 Maintenance Tighten the screw of the clamp until it comes into con- tact with the filter, without tightening. Mark the screw position drawing a line by a felt-tip both on the screw and on the clamp. Make the last tightening of the screw getting it perform 2 turns and 1/4 further the position marked previously.
Page 35 Maintenance Pour around 3 kg of engine oil (as specified in the table BRUTALE on page B-11) into the filling hole. 910 S - R Close the filler hole using the appropriate cap. Only for the Brutale 910 S - 910 R models: Before replacing the filler cap, grease the O-ring (1) with silicone grease (see figure).
Page 36: 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» mark found on the expansion tank (1) and the lower part of the frame tube, that you can see from the ope- ning on the frame protection panel on the left side of the motorcycle.
Page 37 Maintenance Engine coolant substitution Substitution ¡ Every two years Before proceeding the emptying of the system, Perform the following operations in advance: • Remove the ignition switch cover (see “Engine coolant level check”); • Place a container under the engine to collect the used coolant;...
Page 38: Electric Fan Brutale 750 Oro - S / 910 S - R My
Maintenance Complete the assembly of the motorcycle. ELECTRIC FAN (BRUTALE 750 ORO - S / 910 S-R MY 05/06) Check ¡ on pre-delivery and at the first 1000 kilometres and then every 6000 kilome- tres To check the functioning of the electric fan, start the vehicle’s engine and let it warm up.
Page 39: Valve Mechanism Adjustment
Maintenance VALVE MECHANISM ADJUSTMENT Check and adjust ¡ at 1000 kilometres and every 12000 kilometres The valve machanism adjustment must be performed when the engine is cold. Remove in order the following components to carry out the measuring of the play between the camshaft and the valve cups: •...
Page 40 Maintenance Ensure that all the surfaces of the frame are protected by the application of the adhesive tape. Apply the same adhesive tape to the air intakes of the engine. Apply adhesive tape also on the oil breather tube (A) and on the terminals of the accelerator control (B).
Page 41 Maintenance Unscrew the earth bonding on the engine head cover and release the coil harness from the frame removing the two clamps, and extract it on the right side. Unscrew the fixing screws of the coil plates, and remo- ve them. Pull out the coils from their seat.
Page 42 Maintenance For Brutale 910 S-R MY 2007 only Disconnect the coil connectors (1) from the control unit support. Unscrew and remove the coil backing plate fixing screws (1). Remove the coils from their housings. Remove the cover of the secondary air blade (1) by unscrewing the remaining two fixing screws (2).
Page 43 Maintenance Remove the secondary air blade from the head cover, only if inspection is necessary. Operating as shown in the figure, slightly lift up the cylinder head cover. 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 44 Maintenance Remove the head cover gasket. 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. - 28 -...
Page 45 Maintenance Rotate the camshaft by turning the central nut in an anti-clockwise direction to bring piston N° 1 of the engi- ne to the Top Dead Centre position (T.D.C.) when the piston is at its uppermost part of the compression stroke.
Page 46 Maintenance Utilising a feeler gauge of the type shown in the figure, measure the play between the camshaft and the valve cups. Continue measuring the play as illustrated in the figu- The correct measuring of the play is a fun- damental operation for the correct functio- ning of the engine.
Page 47 Maintenance For example, here is a hypothesis of a table in which are written the various values measured. Date Vehicle Engine registration n° Frame registration n° Kilometres travelled Values measured before substituting the valve cups: CYLINDER CYLINDER CYLINDER CYLINDER INDUCTION Valve n°...
Page 48 Maintenance The progressive numeration of each valve is illustrated SCARICO in the photograph on the right. Note the anti-clockwise direction of the numeration. ASPIRAZIONE To facilitate the operation, it is possible to note befo- rehand and in order the play values revealed on the strip of adhesive tape applied to the openings of the air intake conduits.
Page 49 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 fol- lowing valves: Cylinders 3 and 4 intake valves (n° 5,6,7,8) Cylinders 2 and 4 exhaust valves (n°...
Page 50 Maintenance Valve play between the valve cup and the cam Camshaft Upper cup for the springs Adjustment pad Valve cup Valve The play values measured between the valve cup and cam must be the following: For all intake valves 0,15 ÷ 0,24 mm For all exhaust valves 0,20 ÷...
Page 51: Spark Plugs
Maintenance Timing chain, mobile timing chain guide and timing chain tensioner Timing chain and mobile timing chain guide: Check ¡ First 1000 kilometres and then every 12000 kilome- tres 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 descri- bed in the overhaul section of the F4 workshop engine...
Page 52: Fuel Filters
Maintenance Electrode condition 12 N•m Check the electrodes for wear or burning. If they are extre- mely used or burnt, substitute the spark plugs. Also sub- stitute the spark plugs in the case of breakage of the cera- mic isolation or damage to threading. When the spark plugs are renewed, check the thread pitch size and the length of the thread.
Page 53 Maintenance Petrol flange assembly removal Close the tank filler cap. Turn the tank upside down and remove the nine screws (1) fastening the flange to the tank and the three spacers. Remove the flange assembly (2) from its seat. To pull out the flange (2) use three M6 screws (1) remo- ved previously.
Page 54 Maintenance Extract the complete flange assembly (1). Remove the sealing O-rings (1) of the flange (2) and clean them accurately. Check they are undamaged. If damaged, replace them with new rings. Disconnect the electric connectors of the fuel pump (1). - 38 -...
Page 55 Maintenance Remove the fuel probe by using a tube spanner on the fixing nut of the probe. Remove the closing screw (1) of the conduit indicated in the figure so that the remaining fuel flows out of the conduit. Remove the two CLIC R 96135 fasteners (1), placed on top of the fuel filter.
Page 56 Maintenance Operate as indicated in the preceding figure and remo- ve the CLIC R 96135 fastener (1). Remove the fuel filter (1). Extract the fuel pump (1) from its seat. - 40 -...
Page 57 Maintenance Disassemble the fuel filter (1) on the pump and blow in compressed air from inner to outer as shown in the figure. Clean the seat of the fuel pump and the fuel bowl. Remove any residue and ensure that there are no sha- vings that have originated from mechanical work.
Page 58 Maintenance Using fine abrasive paper clean the first threading “cre- sts”of the fuel probe seat as shown in the figure. This operation is necessary to not compromise the good condition of the gasket during the assembly phase of the probe. Place the fuel filter on the pump in according to the timing shown in the figure.
Page 59 Maintenance Insert a new fuel filter (1) within the pipe verifying its right placement (the arrow, marked on the exterior of the body must be oriented as shown in the figure). If necessary, utilise alcohol to facilitate the assembly. Tighten the CLIC R 96 135 fastener (2) – green colour –...
Page 60 Maintenance Insert the pipe on the fuel pump. Facilitate the insertion using alcohol. Assemble the CLIC R 96 135 fastener (1) – green colour – using the CLIC 205 pincers. Assemble the fuel probe (1) on the die-cast flange. When reassembling, substitute the gasket (2) with a new one and lubricate it with silicone grease.
Page 61 Maintenance Reconnect the electrical connectors. It is advisable to clean and degrease the contacts with the correct solvent. Curl the electrical cable (1) into a circle at least twice to contain it in the space. Place the tube (2) so that it is almost into contact with the fuel pump.
Page 62: Fuel Pump Assembly
Maintenance FUEL PUMP ASSEMBLY - 46 -...
Page 63 Maintenance Code Q.ty Note B4 750 ORO B4 750 S B4 910 S B4 910 R I FRAME I I ENGINE I 8A0094275 • • • • 800090927 • • • • 800021480 • • • • 80A090925 • • •...
Page 64 Maintenance Fuel flange unit assembly Before starting the assembly of the flange to the fuel tank, check the condition of the two small overflow tubes connected to the lower part of the fuel filler cap. If these components are not in perfect condition, sub- stitute them and position the band fasteners as shown in the figure.
Page 65: Fuel Union Tubes
Maintenance Insert the flange unit into its seat on the tank. Insert the 6 ÷ 6,5 N•m three spacers into their respective slots located on the flange. Screw and tighten the nine fixing screws. Torque wrench of fuel pump flange fixing screws: 6 ÷...
Page 66 Maintenance The fuel tube with the white CPC union is assembled on the right side of the butterfly body. The fuel tube with the black CPC union is assembled on the left side of the butterfly body. Follow the indication shown in the figure. Orientate the CPC unions as shown in the figure.
Page 67 Maintenance Ensure that the tubes are correctly fitted onto the metal unions of the butterfly body and check that the rubber tubes do not cover the curved section of the metal union. Position the “head” of the fastener as shown in the figu- Fix the fuel tubes to the unions of the butterfly body by utilising the CLIC R 96 135 (green colour) fasteners.
Page 68: Assembly Of Fuel Tubes (Brutale 910 S - 910 R)
Maintenance ASSEMBLY OF FUEL TUBES (BRUTALE 910 S - BRUTALE 910 R) Substitute ¨ At least every three years The procedure to follow in the case of substitution of the feed tubing is as follows: Remove in this order: • Passenger seat •...
Page 69 Maintenance The fuel tube with the white CPC union is assembled on the right side of the butterfly body. The fuel tube with the black CPC union is assembled on the left side of the butterfly body. Connect the tubes using the clamp supplied. Follow the indication shown in the figure For Brutale 910 S –...
Page 70: Throttle Body Adjustment And Tuning
Maintenance THROTTLE BODY ADJUSTMENT AND TUNING (Tickover check, CO synchronisation and check) Check and adjust ¨ First 1000 kilometres and then every 6000 kilome- tres The throttle body adjusting should be performed star- ting the engine of the motorcycle, therefore you should use a flue gas exhauster in order to not saturate the environment with burnt gas.
Page 71 Maintenance Throttle body adjustment and CO check (Brutale 750 ORO-S / Brutale 910 S-R MY 05/06) Verify the parameters of the injection-ignition system by the MDST diagnosis software. Connect the tool cable of the MDST diagnosis with the “Diagnostics” tap on the right side of the motorcycle near the expansion tank of the coolant.
Page 72 Maintenance Check the throttle angle when the throttle is completely closed. • BRUTALE 750 ORO-S: Default value: 1.7° Huntings between 1.5° and 1.7° are allowed only if the engine is started. A value above 1.7° is not allowed. • BRUTALE 910 S-R (MY 05/06): Default value: 2.3°...
Page 73 Maintenance Connect the depression pipes with the vacuometer complying with the match between the pipe and the cylinder which is connected to. In order to perform the following operations, you should provide with the specific tool kit for setting CO. Specific tool: Part code 8000A4686 Remove the sealing caps of the CO drives placed on...
Page 74 Maintenance Remove the seal plate and then the gearcase sealing cap. The by-pass screws must first be adjusted as follows: • BRUTALE 750 ORO-S: One turn from the closed position • BRUTALE 910 S-R (MY 05/06): One and a half turns from the closed position Start the engine and warm it up.
Page 75 Maintenance Balance the pressures in the cylinders: the mercury columns must reach the same height. If all the motor parameters are correctly set, the adju- sting screws should have the following positions: • BRUTALE 750 ORO-S (MY 03): 1 ÷ 1.5 turns from the closed position •...
Page 76 Maintenance The attainment of the correct CO value could involve a variation of the engine speed at minimum. In this case you should operate the by-pass screws again to return the speed to the desired value and then repeat the trimmer adjustment. After having finished the adjustment operations, perform in the order as follows: - assemble the rubber plug on the gearcase lower side;...
Page 77 Maintenance ADJUSTMENT AND CALIBRATION OF THROTTLE BODY (BRUTALE 910 S - R MY 07) After connecting the diagnostic software to the central unit, before starting the engine check the position of the throttle valve: 2.33 degrees (min. 2.1, max 2.5). If it does not fall within the range, use the TPS feature to reset it, WITHOUT TOUCHING THE MECHANIC ADJUSTING SCREW OF THE THROTTLE.
Page 78 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 79 Maintenance To align the throttle body, use the diagnostic software. For the engine to work properly, adjust the throttle body so that the idling regime control works at “mid-range”. To do this, after finding the correct alignment, proceed as follows: If the “lead correction”...
Page 80: Air Filter
Maintenance AIR FILTER Check/substitute Every 6000 kilo- metres Certain parts must be removed in sequence before acceding to the air filter. See chapter C “Bodywork”: • Passenger seat • Rider seat • Left tank side panel • Right tank side panel •...
Page 81 Maintenance Check the condition of the air filter. If it is necessary to substitute it, proceed as follows: Prepare a new air filter. Check that the inside of the air filter compartment is clean and free from foreign bodies. Insert the air filter complying with the correct assembly direction shown in the figure.
Page 82: Bodywork
Maintenance Before proceeding with the assembly of the air filter compartment onto the motorcycle, apply silicone grea- se to the gaskets of the air intake bell chambers. Proceed with the assembly of the parts listed below and according to the procedure described in chapter C “Bodywork”: •...
Page 83: Brakes And Clutch
Maintenance BRAKES AND CLUTCH Check the levels of fluid in the systems¨ At pre-delivery, at first 1000 kilo- metres and then every 6000 kilo- metres Check for leakages¨ At pre-delivery, at first 1000 kilo- metres and then every 6000 kilo- metres Substitute fluid¨...
Page 84 Maintenance In order to access the back brake fluid tank you should remove the fuel tank as described in the Chapter C “Super structures”. Likewise proceed to the front brake fluid tank. Before completing the operation, clean and wash accu- rately the 3 components of the chamber cover using alcohol and blow to dry them.
Page 85 Maintenance Check eventual leaks and blow-bys of brake and clut- ch fluid on the unions and tubing. If any breakages are seen, substitute the damaged parts as described in chapter H “Brakes”. Brake fluid leakages are dangerous and immediately discolour painted surfaces. Before riding, check the tubes and joints of the brakes for damage and signs of leaks.
Page 86: Brake/Clutch/Gearchange Commands Check
Maintenance BRAKE/CLUTCH/GEARCHANGE COMMANDS CHECK It is possible to effectuate the adjustment of the posi- tion of the levers of the front brake, the clutch and also the gearchange lever. Such adjustments have been created to optimise the grip and the movement of the commands with regards to the needs of the motorcy- clist.
Page 87 Maintenance Gearchange/rear brake lever adjustment To carry out the adjustment of the rear brake lever and the gearchange lever, slacken the screw (1) utilising a 5 mm.Allen key. Adjust the position according to the requirements of the rider utilising the same key and on the hexagonal hole (2).
Page 88: Brake Pads
Maintenance BRAKE PADS Front brake caliper Check/substitute ¨ At the first 1000 kilo- metres and then very 6000 kilometres Check the condition and thickness of the brake pads on the calipers. Rear brake caliper Measure the thickness of the pad linings. If the thick- ness of the linings is equal or less than the wear limit shown below, replace the pads as described in chapter H “Brakes”.
Page 89: Dair Intake Injection System
Maintenance After making adjustments, check that the throttle val- ves open slightly by activating the choke lever (1), as indicated in the following figure. If interventions have been carried out on the throttle bodies, the transmission of the accelerator control must be analysed not only at the accelerator handgrip but also near to the throttle bodies.
Page 90: Locks
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 91 Maintenance Fuel cap lock Lift up the anti-dust cover. Insert the key, rotating it in a clockwise direction and lift up the cap. After refuelling, press the cap down and rotating the key contemporaneously to facilitate the closure. Press and hold the cap, let the key go free, bring it into a lon- gitudinal position and pull it out.
Page 92: Steering
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 ¨...
Page 93 Maintenance Adjust¨ At the first 1000 kilometres and then every 6000 kilometres To adjust the chain tension, proceed as follows: Slightly loosen the 2 screws of the back wheel hub until they can freely turn. Using the special spanner as indicated in the figure, move the eccentric adjuster nut backwards or forwards respectively slackening or tightening the chain, until the correct play is reached (as described previously).
Page 94 Maintenance Chain lubrication Lubricate¨ At the first 1000 kilometres and at 6000 kilometres and then at every 12000 kilometres Clean the chain with a clean cloth and/or a jet of air. The chain is the type with sealing rings (O- RING);...
Page 95: Tyres
Maintenance TYRES Check pressures¨ At the pre-delivery, at the first 1000 kilometres and then every 6000 kilometres Check wear ¨ At the first 1000 kilometres and then every 6000 kilometres If the tyre pressures are too high or too low, the ride is affected and tyre life duration is accentuated.
Page 96: Wheels
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 planarity, the eccentricity and the ovalisation of the wheel. See the control procedures described in chapter F “Suspension and wheels”.
Page 97: Rear Wheel Hub
Maintenance REAR WHEEL HUB Check and lubricate bearings ¨ Every 12000 kilometres Substitute ¨ Every 12000 kilometres To check and overhaul the rear wheel hub unit, it is necessary to carry out certain preliminary operations by consulting the relative chapters. Remove the rear wheel (see chapter F “Suspension and wheels”).
Page 98: Side Stand
Maintenance Compression and extension adjustment (rear suspen- sion): CLICK! (See the Adjustments Table - Chapter “F – SUSPEN- CLICK! CLICK! CLICK! CLICK! SION AND WHEELS” - page 36) . CLICK! This operation can be made with the N.B. shock absorber in position on the motorcycle.
Page 99: Front Fork
Maintenance FRONT FORK Substitute oil ¨ every 24000 kilometres The front fork is vitally important for the rideability and roadholding of the motorcycle. It is therefore necessary to substitute the fork oil at the prescribed intervals. Quantity oil: about 665 cc Specified oil: - Brutale 750 ORO / 750 S (MY 03): SAE 5 - Brutale 750 S (MY 04):...
Page 100: Electrical System
Maintenance ELECTRICAL SYSTEM Check the functioning ¨ At the pre-delivery, at the first 1000 kilometres and then every 6000 kilometres Carry out a detailed check on the various parts of the electrical system, the contacts between components and their good functioning. Consult chapter E “Electrical system”...
Page 101 Maintenance Turn the screw of the positive terminals and tighten them complying with the prescribed torque by using a torque wrench. Torque wrench setting: 7 ÷ 8 Nm 7 ÷ 8 N•m When the leads are mounted, replace the protection cover on the positive pole (see the figure).
Page 102 Maintenance Turn the screw of the negative terminals and tighten them complying with the prescribed torque by using a torque wrench. Torque wrench setting: 7 ÷ 8 N•m Before tightening, verify that the cables are correctly oriented. 7÷8 N•m At the end of assembly, ensure that the cable of the positive terminal is placed inside the structure of the back sub-frame (see the figure).
Page 103: Instruments And Warning Lights
Maintenance INSTRUMENTS AND WARNING LIGHTS Luminous warning Luminous warning indication light Check › At the pre-delivery, at the first 1000 indication light kilometres and then every 6000 kilo- metres The instrumentation check must be carried out com- button Tachometer pletely on all its functions as listed in the following list. If even one of the functions does not function correctly, consult chapter E “Electrical system”...
Page 104 Maintenance Multi-function display 10 Speedometer The speedometer indicates the speed. The value of the scale can be written in kilometres per hour (k.p.h.) or miles per hour (m.p.h.). The highest value on the scale is 299 k.p.h. (185 m.p.h.). 11 “SET” button If pressed, the “SET”...
Page 105 Maintenance Modifications to the display functions Modifications can be made to the clock function, the tripmeter function and the thermometer function. This operation must be effectuated with the engine switched on and the gears in neutral. Clock (hours and minutes) Repeatedly press the starter button until the visualisa- tion of the hour appears.
Page 106 Maintenance Press the starter button to pass from kilometres per hour to miles per hour and vice versa. Varying the measuring unit of the speedometer automatically varies also the mileometer (total and partial). Press the “SET” button. The measuring unit of the ther- mometer starts to flash.
Page 107 Maintenance Resetting of the tripmeters The values of the “TRIP 1” and “TRIP 2” can be reset as follows. Press the starter button to activate the “TRIP 1”. Press the starter button for more than four seconds. The value will start to flash. Press the starter button for less than four seconds;...
Page 108: 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. Dipped headlamp – bulb substitution Remove the two side fixing screws (1) of the front headlight.
Page 109 Maintenance Put the headlamp on a table in order to perform the fol- lowing operations. Remove the back screw of the headlamp. Remove the front part of the headlamp from its support shell. Disconnect the connector of the dipped headlight. Remove the protection cover.
Page 110 Maintenance Dipped headlight – Replacing bulb Turn the bulb of the dipped headlight counterclockwise and extract it from its seat. Disconnect the connector from the bulb. Do not touch the glass of the bulb with your hands. In case of contact clean using a degreasing product.
Page 111 Maintenance To extract the bulb press it counterclockwise. Insert the new bulb pressing and turning it clockwise. Reassemble the glass and retighten the fixing screw. Rear direction indicators – bulb substitution Remove the fixing screw. Remove the glass. To extract the bulb press it counterclockwise. Insert the new bulb pressing and turning it clockwise.
Page 112 Maintenance Rear light/stop light – bulb substitution Lift the passenger seat. Extract the bulb holder, rotating it in an anti-clockwise direction. To extract the bulb, press it down and rotate it in an anti-clockwise direction. Insert the new bulb pressing and turning it clockwise. Reinsert the bulb holder and rotate it in a clockwise direction.
Page 113 Maintenance Following the procedure shown in the figure, lower the cable guide separating it from the upper supporting surface. Extract the lamp holder of the number plate light from its seat. Extract the bulb taking it out from the lamp holder. Insert the new bulb.
Page 114 Maintenance The fuses are situated on the right side of the motorcy- cle; to reach them you should disassemble the right side panel fixed on the tank. Remove the cover. Turn the ignition switch on “OFF” before checking or replacing the fuses in order to avoid accidental short circuits with conse- quent risk to damage other electric compo- nents.
Page 115: Front Headlamp
Maintenance Replace the burnt fuse and reassemble the cover. Remember that three spare fuses are available in the toolkit. Never use a fuse having an adjustment diffe- rent from the instructions in order to avoid from damaging the electrical system of the motorcycle with the consequent fire risk.
Page 116 Maintenance Adjusting front headlight Place the motorcycle 10 metres from a vertical wall. Ensure that the ground is even and that the optical axis of the projector unit is perpendicular to the wall. The motorcycle must be in a vertical position.. Measure the height of the centre of the beam from the ground and mark it with a cross on the wall using a piece of chalk.
Page 117 Bodywork SECTION Revision 1 - 1 -...
Page 118 Bodywork SUMMARY FAIRING ASSEMBLY ..........................Page 3 DISASSEMBLING FRONT HEADLAMP....................Page 4 DISASSEMBLING INSTRUMENTATION PANEL .................Page 5 DISASSEMBLING HANDLEBAR ......................Page 6 DISASSEMBLING HEADLIGHT SUPPORT ..................Page 7 FUEL TANK..............................Page 8 FUEL TANK SIDE PANEL REMOVAL ....................Page 9 FUEL TANK REMOVAL.........................Page 10 AIR FILTER COMPARTMENT........................Page 15 AIR FILTER COMPARTMENT REMOVAL ....................Page 16 AIRBOX REMOVAL ..........................Page 18 TAIL UNIT..............................Page 21...
Page 119: Fairing Assembly
Bodywork FAIRING ASSEMBLY - 3 -...
Page 120: Disassembling Front Headlamp
Bodywork DISASSEMBLING FRONT HEADLAMP Disassemble the two fixing screws of the headlamp. Release the headlamp from the support for the lumi- nous beam height control. Disconnect the electric connection (1) and remove the headlamp. - 4 -...
Page 121: Disassembling Instrumentation Panel
Bodywork DISASSEMBLING INSTRUMENTATION PANEL Unscrew the fixing screws and remove the instrumen- tation panel cover by acting in the shown direction. Loosen the rubber cowl (1) and unhook the connector. Unscrew the fixing screw of the instrumentation panel and withdraw it from the support. - 5 -...
Page 122: Disassembling Handlebar
Bodywork DISASSEMBLING HANDLEBAR Before performing this operation, you should prelimi- narily carry out the disassembling of the front headlight and the instrumentation panel as described in the pre- vious pages. Disconnect the connectors. If removal of the headlamp is required, unhook the headlamp support cables.
Page 123: Disassembling Headlight Support
Bodywork Unscrew the four fixing screws of the handlebar U bolt. Remove the handlebar with the U bolt. 20 N•m During the reassembly, you should pay attention to the right positioning of the U bolt in regard to the handlebar. This is made using a pin that you have to insert in the right seating of the handlebar.
Page 124: Fuel Tank
Bodywork FUEL TANK - 8 -...
Page 125: Fuel Tank Side Panel Removal
Bodywork Before removing the fuel tank you should preliminarily remove passenger and rider seats as described at the paragraph “Disassembling tale unit” of this chapter. Remove the ignition commutator protection by unscrewing the two fixing screws (1). FUEL TANK SIDE PANEL REMOVAL Operate on the left side of the motorcycle.
Page 126: Fuel Tank Removal
Bodywork Release definitely the side panel by moving it towards the rear part in order to release it from the special rub- bered screw (1) fastened to the fuel tank. Make the same operations in order to remove the right side panel.
Page 127 Bodywork Operate on the right side. Unscrew and remove the special rubbered screw (1) on the tank support. Unscrew and remove the two support fixing screws (1) of the tank support. Make the same operations on the left side of the motorcycle in order to remove the tank support.
Page 128 Bodywork Lift and lean the fuel tank on a side in order to easily work on the rapid unions on the fuel pump flange. In order to make the unions disengagement N.B. operation from the fuel pump flange easier it’s recommended the presence of two ope- rators, one that works on the tank support and the other on the rapid unions release.
Page 129 Bodywork Disconnect the connector of the fuel flange pump (1) of the main wiring. Withdraw the fuel breather pipe (1) connected to the three-way union. Removing of the fuel tank plug Insert the motorcycle key in the fuel plug lock, rotate clockwise and open the plug.
Page 130 Bodywork Unscrew and remove the three screws (1) and the safety screw (2). During the reassembly of the fuel tank plug make the same operations in the opposite direction in regard to disassembling ones by tightening them at the descri- bed torque and apply the indicated brakethread.
Page 131: Air Filter Compartment
Bodywork AIR FILTER COMPARTMENT BRUTALE 910 S-R Euro 3 BRUTALE 910 BRUTALE 910 S-R Euro 3 S-R Euro 2 - 15 -...
Page 132: Air Filter Compartment Removal
Bodywork AIR FILTER COMPARTMENT REMOVAL Before removing the air filter compartment you should primarily remove the fuel tank as described in the para- graph “Tank” of this chapter. Preliminary operations (Brutale 750 ORO - S / Brutale 910 S-R MY 05-06) Unscrew and remove the fixing nut (1) of the earth wiring of the gearcase.
Page 133 Bodywork Disconnect the connection to the gearcase from the main wiring. Preliminary operations (Brutale 910 S-R MY 2007) After loosening the clamp, disconnect the secondary air hose from the hose airbox. Disconnect the temperature sensor connector (1) and air pressure sensor. - 17 -...
Page 134: Airbox Removal
Bodywork AIRBOX REMOVAL Release the fixing springs (1) of the air filter compart- ment box to the throttle body. Unscrew and remove the two side fixing screws (1) of the air filter compartment to the frame. Disconnect the breather piping (1) from the block. - 18 -...
Page 135 Bodywork Unscrew and remove the two fixing screws (1) and the air filter compartment locking support (2). Remove the air filter compartment from the throttle body. During the reassembling make the same operations of the disassembling paying attention to tighten the fixing screws (1) of the ignition commutator to the described torque wrench.
Page 136 Bodywork If you had to remove the fixing screws of the throttle body springs (1), during their reassembling apply the described brakethread and tighten them to the indica- ted torque. Torque wrench of the fixing screws of the throttle body fly springs: 5 ÷ 7 N•m Apply Loctite 243 5÷7 N•m - 20 -...
Page 137: Tail Unit
Bodywork TAIL UNIT REMOVAL TAIL UNIT Insert the ignition lock key in the opening seat lock on the left side of the motorcycle and rotate it clockwise. In the meantime push lightly on the passenger seat. The lock will be released. Remove the passenger seat.
Page 138 Bodywork TAIL UNIT REMOVAL Insert the ignition lock key in the opening seat lock on the left side of the motorcycle and rotate it clockwise. In the meantime push lightly on the passenger seat. The lock will be released. Remove the passenger seat. Release the fixing clip of the rider seat and remove it from its seat by lifting it.
Page 139 Bodywork Unscrew and remove the three upper screws (1) and the lower fixing screw of the rear fairing panels on both sides, taking care to recover the nylon washers (2). After that remove the side panels. Extract the lamp holder of stop and side light from its seat.
Page 140 Bodywork Unscrew the four fixing screws of the rear part tale unit. Remove the rear part of the tale unit. Release the electric connector and remove the lamp holder of the tail and stop light with the wiring. - 24 -...
Page 141: Under-Tail Assembly
Bodywork UNDER-TAIL ASSEMBLY - 25 -...
Page 142: Disassembling Under Tale Unit
Bodywork DISASSEMBLING UNDER TALE UNIT Disassemble the passenger and rider seats, the side panels and the rear tail piece as described in the pre- vious paragraph “Disassembling tale unit”. Disconnect the connection of the direction indicator and of the number plate light. Unscrew the three fixing screws of the number plate holder.
Page 143 Bodywork Unscrew the fixing screws of the battery connections and remove it from its seat. Disconnect the negative pole first. Release the connector from the solenoid starter. Remove the fixing screw of the starter. - 27 -...
Page 144 Bodywork Unscrew the under tale unit fixing screws. For Brutale 910 S-R MY 2007 only Unhook the pressure drop sensor connector. Remove the under tale unit. - 28 -...
Page 145 Air intake injection system SECTION Revision 1 - 1 -...
Page 146 Air intake injection system SUMMARY INJECTION-IGNITION SYSTEM ......................PAGE 3 INJECTION SYSTEM TECHNICAL CHARACTERISTICS ...............PAGE 3 INJECTION TIME (INJECTION VOLUME)....................PAGE 3 INJECTION TIME COMPENSATION......................PAGE 4 INJECTION ARREST CONTROL ......................PAGE 4 IGNITION SYSTEM............................PAGE 5 POSITIONS OF ENGINE-CONTROL SYSTEM PARTS (BRUTALE 750 ORO S - 910 S-R MY05-06)...PAGE 6 POSITIONS OF ENGINE-CONTROL SYSTEM PARTS (BRUTALE 910 S-R MY 2007) ......PAGE 7 FUEL PUMP CONTROL SYSTEM ......................PAGE 8 COMPONENTS ............................PAGE 10...
Page 147: Injection-Ignition System
Air intake injection system INJECTION-IGNITION SYSTEM The injection-ignition system is of the "alpha/N” type. The motor r.p.m. and the throttle position are used as main parameters to measure the amount of intake air to find the amount of fuel to be injected. The amount of intake air for each cycle depends on the density of the air in the intake collector, the single displa- cement and the volumetric efficiency: this last is determined experimentally on the engine for the entire functio- ning range (rounds and engine load) and it is stored in the dimensioned plans (maps) inside the EPROM of the...
Page 148: Injection Time Compensation
Air intake injection system INJECTION TIME COMPENSATION The various sensors allow the injection time (volume) compensations to be carried out on the basis of the following 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 of the fuel injected) to compensate the lower presence of oxygen in the atmosphere.
Page 149: Ignition System
Air intake injection system IGNITION SYSTEM DESCRIPTION The system belongs to the family of integrated systems of digital electronic ignition with advance static timing and electronic fuel injection of the semi-phased intermittent type (injected and ignition simultaneously to cylin- ders 1-4 and 2-3). This ignition system consists of an engine crankshaft position sensor (pick-up), an ECU, four ignition coils of the top plug type and four spark plugs.
Page 150 Air intake injection system - 6 -...
Page 151 Air intake injection system - 7 -...
Page 152: Fuel Pump Control System
Air intake injection system FUEL PUMP CONTROL SYSTEM When the ignition switch is switched to the "ON" position, the current from the battery reaches the motor of the fuel pump via the side stand relay and the pump relay thereby switching on the motor. 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 153 Air intake injection system Fuel feed system The fuel feed system consists of the tank, pump, filter, feed tube, feed tubes (including the fuel injectors), regu- lator of the pressure and the fuel return tube. The fuel in the tank is pumped into the feed tubing at a controlled pressure by the relative regulator and maintained at a certain constant value higher than the suction generated by the motor.
Page 154: Components
Air intake injection system COMPONENTS Fuel pump The electric fuel pump that is situated inside the fuel tank consists of an electric motor, of the rotor, impeller, con- trol valve and pressure release valve. The ECU controls the ON/OFF condition as described in the section FUEL PUMP CONTROL SYSTEM. When electrical energy is supplied to the pump, the motor switches on and the impeller activates.
Page 155 Air intake injection system Fuel pressure regulator The fuel pressure regulator is a diaphragm pressure release valve that consists of a diaphragm, spring and valve. It always maintains the pressure of the fuel sent to the injector at 3.0 kg/cm2 (300 kPa). When the pressure of the fuel rises above 3.0 kg/cm2 (300 kPa) the excess fuel opens the valve of the regulator and therefore can return to the fuel tank.
Page 156: Sensors
Air intake injection system SENSORS Atmospheric air temperature/pressure The air intake sensor is situated on the right side of the air filter compartment and indicates both the atmo- spheric pressure and the air temperature. Intake air pressure sensor The sensor reveals the pressure of the intake air and this pressure is therefore converted into voltage that is sent to the ECU.
Page 157 Air intake injection system Intake air temperature sensor The temperature of the intake air is found measuring the resistance of the Thermistor. The resistance value read is proportionate to the voltage read by the ECU. The volume of fuel injected increases when the intake air temperature is low. The resistance of the Thermistor increases when the air temperature is low and diminishes when the temperatu- re is high (NTC type sensor).
Page 158 Air intake injection system Throttle body position The sensor of the throttle position is situated on the right side of the throttle body. This sensor is a potentiometer with a resistance which varies according to the opening angle of the accelera- tor.
Page 159: Engine Pick-Up
Air intake injection system ENGINE PICK-UP The r.p.m./TDC sensor is of an inductive type and is situated on the left side of the motorcycle. To check this component it is necessary to identify the relative connector positioned as shown in the figure, inside the frame on the right side of the motorcycle.
Page 160: 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 161: Diagnostics System
Air intake injection system DIAGNOSTICS SYSTEM Ignition and injection system diagnostics For the diagnosis of the ignition and injection system A Weber-Marelli diagnostic software is available which is capable of identifying and recording the faults present or that were present previously on the motorcycle. This software is equipped with a guide book for the use of the software itself to carry out checks on each indivi- dual component of the system.
Page 162: Injection System - Electrical Diagram
Air intake injection system INJECTION SYSTEM - ELECTRICAL DIAGRAM - 18 -...
Page 163 Air intake injection system MV Agusta Brutale Oro – S Engine control unit pinout Description Type of signal cylinders 1-4 coil control power output Latch relay control digital output Injectors 2-3 control power output engine enabling from safety logics digital input...
Page 164 Air intake injection system - 20 -...
Page 165: Eelectrical System
Electrical system SECTION Revision 2 - 1 -...
Page 166 Electrical system SUMMARY CONNECTORS ............................PAGE 3 COUPLINGS ..............................PAGE 3 FUSES................................PAGE 3 SEMICONDUCTOR PARTS........................PAGE 4 ELECTRICAL DIAGRAM BRUTALE 750 ORO-S / 910 S-R MY 05/06) ..........PAGE 5 PARTS LIST ............................PAGE 6 ELECTRICAL DIAGRAM BRUTALE 910 S – R (MY 2007) ..............PAGE 7 PARTS LIST ............................PAGE 8 BATTERY ..............................PAGE 9 INITIAL BATTERY CHARGE ........................PAGE 9...
Page 167: 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 168: Semiconductor Parts
Electrical system SEMICONDUCTOR PARTS INCORRECT • Pay special attention to not drop parts incorporating semiconductors (ECU, instrument panel, CPU). • When checking these components, carry out the instruction strictly. The lack of using the correct pro- cedure can cause grave damage. - 4 -...
Page 169: Electrical Diagram Brutale 750 Oro-S / 910 S-R My 05/06)
Electrical system ELECTRICAL DIAGRAM BRUTALE 750 ORO-S / 910 S-R (MY 05/06) - 5 -...
Page 170: Parts List
Electrical system PARTS LIST Parts list Parts list Parts list Ref. Description Ref. Description Ref. Description Solenoidd Instrument panel 17-18 Air temperature/pressure sensor Number plate light Injectors Iniettori 19-20 Left indicator Right indicator Butterfly potentiometer Horn Left indicator Water temperature sensor – CPU Water temperature sensor for instrument ther- Diagnostic connector Oil switch...
Page 171: Electrical Diagram Brutale 910 S - R (My 2007)
Electrical system ELECTRICAL DIAGRAM BRUTALE 910 S – R (MY 2007). P U S H D O W N F R E E - 7 -...
Page 172: Parts List
Electrical system PARTS LIST Parts list Parts list Parts list Rif. Description Rif. Description Rif. Description Butterfly potentiometer Light switch Water temperature sensor – CPU Frame/CPU earth Number plate light Oil switch Battery recharge Right indicator Electric fan Clutch switch Left indicator Fuses Starter motor...
Page 173: Battery
Electrical system BATTERY The battery mounted on this motorcycle is a sealed battery therefore no maintenance is required. The batteries recommended are the following: - YUASA YTZ10-S (pre-activated). INITIAL BATTERY CHARGE Proceed with charging following the method on the packet that the battery came in or as indicated in the following table.
Page 174 Electrical system Remove the passenger seat as shown in the figure. Rotate the rider seat fastener as shown in the figure. Lift up the rider seat and remove it. - 10 -...
Page 175 Electrical system Insert the battery into the appropriate compartment. The initial battery charge should be carried out before mounting it on the motorcycle. Battery terminal assembly Assemble the two positive (+) terminal leads on the relative battery pole, respecting the order shown in the figure.
Page 176 Electrical system When the terminals are mounted replace the protec- tion cover on the positive pole (see figure). Connect the two negative (-) terminal leads to the rela- tive pole of the battery respecting the placing shown in the figure. Rotate the screw of negative terminal leads and tighten to the prescribed torque, using a torque wrench.
Page 177 Electrical system After the assembly operation, make sure that the positive terminal cable is positioned correctly inside the rear frame unit (see figu- re). POSIZIONAMENTO E MONTAGGIO DEI TERMINALI (CAPICORDA) SULLA BATTERIA. PLACEMENT AND ASSEMBLY OF TERMINALS (WIRE TERMINALS) ON THE BATTERY NEGATIVE WIRE (-) CAVO NEGATIVO (-) NEGATIVE POLE (-)
Page 178: Charging System
Electrical system CHARGING SYSTEM The system of the charging circuit illustrated as follows is substantially composed of a generator and a rectifier/regulator, enclosed in one component. The alternating current (AC) is transformed into direct current (DC) by the rectifier, regulated and therefore utilised for charging the battery.
Page 179 Electrical system In the preceding diagram is illustrated the complete charging circuit. The input circuit of the regulator includes the integrated M-IC that, being complex in its various functions will be simply indicated as M-IC. (1) Ignition switch “ON” with engine off. Ignition Switch Stator coil...
Page 180 Electrical system (2) Recharging (voltage less than the regulated voltage). Ignition Switch Stator coil Charge Lamp M.IC Rotor coil IC Regulator Once the engine is switched on, the M-IC makes the Tr1 pass from an intermittent “ON” and “OFF” condition to a stabilised “ON”...
Page 181 Electrical system (3) Recharge (voltage more than the regulated voltage). Charge Current Ignition Switch Stator coil Charge Lamp M.IC Rotor coil IC Regulator The moment in which the Tr1 is stabilised in the “ON” position the voltage at terminal B increases and when the voltage at terminal S exceeds the regulated voltage (approximately 14.5V at 25°), the I-MC realises it and puts the Tr1 in the “OFF”...
Page 182 Electrical system (4) Rotor coil disconnected. Charge Current Ignition Switch Stator coil Charge Lamp M.IC Rotor coil IC Regulator If the rotor coil is disconnected whilst the generator is functioning, the generator interrupts the current and the vol- tage at terminal P goes to zero. The M-IC reveals this condition and through the Tr3 switches on the warning light.
Page 183 Electrical system (5) Disconnection of terminal S of the regulator. Charge Current Ignition Switch Stator coil Charge Lamp M.IC Rotor coil IC Regulator If a reference voltage does not arrive at terminal S whilst the alternator is functioning, the M-IC reveals it and through Tr3 switches on the warning light.
Page 184 Electrical system (6) Terminal B disconnected. Charge Current Ignition Switch Stator coil Charge Lamp M.IC Rotor coil IC Regulator Connettore a 4 vie 4 ways connector If terminal B is disconnected whilst the alternator is functioning, the voltage of the battery gradually drops until it starts discharging.
Page 185 Electrical system A list of possible problems that could occur when the warning light is switched on. Incorrect contact at terminal B or the 4- Repair the fault. way coupling; interruption of the system The light still remains on. including the fuses or short circuit. There is a short circuit between terminal Repair the fault.
Page 186: Battery Efficiency Check
Electrical system BATTERY EFFICIENCY CHECK Battery current loss check • Remove the tail unit as described in chapter C “Bodywork”. • Turn the ignition switch to the “OFF” position. • Disconnect the cable from the negative (-) pole of the battery.
Page 187 Electrical system Charge feed check • Remove the tail unit • Switch on the engine and run it at 2000 r.p.m. with the light switch in the “ON” position and the selector on main beam Hl. Measure the voltage between the positive (+) and negative (-) terminals of the battery with a multi-tester.
Page 188: Cpu
Electrical system The CPU includes a group of functions previously performed by other components of the motorcycle. This allowed to simplify wiring and to reduce connections. The general reliability of the unit is enhanced and overall weight is reduced. FUNCTION DIAGRAM ELECTRICAL SYSTEM IGNITION SWITCH FUEL-INJECTOR-COIL PUMP...
Page 189: Starter System
Electrical system STARTER SYSTEM The diagram below represents the starter system. KILL INTERRUTTORE SISTEMA - ACCENSIONE IGNITION INJECTION SWITCH SPEGNIMENTO INIEZIONE SYSTEM 7.5A POSITIVE TER- POSITIVO MINAL – BAT- BATT. TERY N.O. IN CENTRALINA ECU 1.6 M 1.6M N.O. BATT +BATTERY + BATTERIA STARTER...
Page 190 Electrical system - 26 -...
Page 191 Electrical system - 27 -...
Page 192 Electrical system - 28 -...
Page 193 Electrical system - 29 -...
Page 194 Electrical system - 30 -...
Page 195 Electrical system - 31 -...
Page 196 Electrical system - 32 -...
Page 197 Electrical system - 33 -...
Page 198: Fuses
Electrical system Electrical system FUSES The fuses are situated on the right side of the motorcy- cle. To reach them it is necessary to remove the tank side panel and the cover. Substitute the burnt fuse and replace the cover (find the electrical fault before replacing the fuse).
Page 199: Starter Motor Check
Electrical system STARTER MOTOR CHECK If a fault has been diagnosed in the starter motor, it is necessary to proceed as follows with the check: • Connect a tester between earth and the starter motor terminal. • Check that there is continuity between the positive pole and the engine earth.
Page 200 Electrical system Starter relay check Remove the rider seat, disconnect the battery. Unhook the connector from the starter relay. Unscrew the fixing screw of the relay. Disconnect the cables of the starter motor and the positive cable of the battery from the relay. - 36 -...
Page 201: Ignition/Side Stand Safety System Parts Check
Electrical system Apply 12 volts to the terminals (1) and (2) of the relay and check the continuity between terminals B-M. Do not apply the battery voltage to the starter relay for more than five seconds to avoid overheating and therefore damaging the winding. - Using a multi-tester, check that the winding is on open circuit or if a resistance is present.
Page 202: Gearchange Position Switch
Electrical system GEARCHANGE POSITION SWITCH The connector of the gearchange position switch is placed in the proximity of the side stand and motorcy- cle speed sensor connectors. The connector of the gearchange position switch dif- fers from the side stand connector since it is identified by an S marked on the electric system sheathing.
Page 203: Spark Plugs
Electrical system If it is necessary to substitute the switch proceed by unscrewing the two fixing screws. SPARK PLUGS To accede to the ignition spark plugs, it is necessary to remove the following components: • Tail unit • Left side panel •...
Page 204: Run Off Safety Switch
Electrical system Unscrew the fixing screws of the coil plates and remo- MY 2007 ve them. Remove the coils from their seats. When reassembling the coils, take care to connect the map connector correctly. If not connected or if connected incorrectly, it could cause damages to the coils themselves.
Page 205 Electrical system Remove the relative connector to the right hand control group as indicated in the figure. Remove the plug part of the connector. With the switch in the “RUN” position, check the conti- nuity between pins (1) and (2). - 41 -...
Page 206: Instrumentation
Electrical system INSTRUMENTATION If faults are found in the instrumentation, it is necessary to check the main wiring and the various components related to the instrumentation. To carry out the various checks, remove the instrument panel cover, then move aside the rubber cap and the connector situated behind the instrumentation.
Page 207: Oil Pressure Sensor
Electrical system OIL PRESSURE SENSOR With the engine switched off, it is necessary to find continuity between the terminal of the sensor and the earth of the motorcycle (as shown in the figure). With the engine switched on, the contact must be open.
Page 208: Instrument Panel Water Sensor
Electrical system INSTRUMENT PANEL WATER SENSOR Connect a resistance between the two connections of the connector as shown in the table. Turn the ignition key to the "ON" position. At this point the display should indicate the Temperature relative to the resistance applied. It is sufficient to carry out the test at 50°...
Page 209: Left Direction Indicator
Electrical system LEFT DIRECTION INDICATOR If the left direction indicator warning light does not func- tion, there must be the presence of voltage input inter- mittently between pin (13) and pin (20). If the presence of input voltage is verified, the conti- nuity between pin (13) of the instrument panel and pin (5) of the left hand control connector must be checked.
Page 210: Cooling Fan System
Electrical system If the fuse in question is in good condition, proceed with the check of the speed sensor as follows: 1) Remove the sensor from the motorcycle as descri- bed in the “F4 workshop engine manual (Code 8000A1592). 2) Disconnect the connector, check that there 10 kΩ is measured between terminals (1) and (2) of the con- nector.
Page 211: Klaxon
Electrical system KLAXON A fault in the klaxon system should be checked at various points: • Check the condition of fuse 11 in the fuse box on the right side of the motorcycle. • If the fuse is in good condition, disconnect the con- nector of the left control and check the continuity between contact 34 of the control with the klaxon but- ton pressed as in the following page under “Switches”.
Page 212: 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. - 48 -...
Page 213: Suspension And Wheels
Suspension and wheels SECTION Revision 3 - 1 -...
Page 214 Suspension and wheels SUMMARY FRONT WHEEL ..............PAGE 3 FRONT WHEEL REMOVAL (BRUTALE 750 ORO - 750 S - 910 S) .
Page 215: Front Wheel
Suspension and wheels FRONT WHEEL N·m 20 ÷ 22 40 ÷ 44 38 ÷ 42 60 ÷ 65 42 ÷ 46 12 ÷ 14 5 ÷ 7 Torque Kg·m pressure ft·lb Operation Description BRUTALE 750 ORO BRUTALE 750 S BRUTALE 910 S BRUTALE 910 R FRONT WHEEL Material...
Page 216: Front Wheel Removal (Brutale 750 Oro - 750 S - 910 S)
Suspension and wheels Before proceeding with the removal and overhaul of the components relative to the front suspension, it is advisable to remove beforehand the front mudguard as described in detail in chapter H “Brakes”. Place the motorcycle on the rear stand. Special tool: N.
Page 217: Front Wheel Removal (Brutale 910 R)
Suspension and wheels Remove the screw (1) on both front wheel/fork attach- ments. During this operation, it is necessary to sup- port the wheel. FRONT WHEEL REMOVAL (BRUTALE 910 R) Unscrew the two fixing screws (1) of both front calipers and remove the calipers.
Page 218 Suspension and wheels Loosen the two screws (1) on the fork pin on the right side of the vehicle. During this operation, it is necessary to sup- port the wheel. Loosen the two screws (2) on the fork foot on the left side of the vehicle.
Page 219 Suspension and wheels Front wheel bearing check Only for the B4 910 R model, the following preliminary operations must be performed: - Fit the axle on the front wheel. - Turn in and bring the threaded bushing (Part Code 8000A3469) into contact with the wheel spindle, tighte- ning it by hand.
Page 220 Suspension and wheels Introduce the extractor until the internal ring of the bea- ring is hooked up. Introduce the wheel spindle and screw and manually block them. Mount the flange, spacer ring and nut utilising a 14 mm spanner and a 27 mm spanner and extract the bearing as shown in the figure.
Page 221 Suspension and wheels Reassembly – front wheel bearings Before proceeding with the reassembly, accurately clean the bearing seats in the wheel hub. Lubricate the outer race of both bearings with special grease. Mount a bearing onto the special tool. Recommended product: AGIP GREASE 30 Special tool N.
Page 222 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 223: Front Wheel Assembly (Brutale 750 Oro - 750 S - 910 S)
Suspension and wheels FRONT WHEEL ASSEMBLY (BRUTALE 750 ORO - 750 S - 910 S) If the front tyre is substituted, before assem- bling the wheel it is necessary to balance the wheel following the indications in page 69. 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 224 Suspension and wheels Position the wheel and insert the axle (1) from the right side of the vehicle. Ensure that the bushing on the left fork N.B. foot is in place and in contact with the foot, with the fixing screws slightly tightened in order to prevent them from coming out while inserting the axle.
Page 225 Suspension and wheels Remove the front stand and rest the front wheel on the ground. While pulling the front brake lever, push down on the front suspension two or three times to allow the right- hand fork rod to position itself properly. Tighten the right (4) and left (5) fork foot screws.
Page 226: Front Fork
Suspension and wheels FRONT FORK N·m 8 ÷ 10 8 ÷ 9 16 ÷ 18 22 ÷ 24 20÷22 12÷14 Torque Kg·m pressure ft·lb Operation Description Brutale 750 ORO Brutale 750 S Brutale 910 S Brutale 910 R FRONT SUSPENSION Type Hydraulic telescopic forks with the stems positioned upside down, equipped with an external adjustment system for extension, compression and spring preload...
Page 227: Front Fork Overhaul
Suspension and wheels FRONT FORK OVERHAUL Remove the front wheel as described in the paragraph ”Front wheel removal” of this Chapter. Only for the Brutale 910 R model: N.B. Before continuing with the other operations, loosen the two screws (1) on the fork on the left side of the vehi- cle and remove the bushing (2).
Page 228 Suspension and wheels Slacken the fork cap (1). Completely unscrew the cap and lower the sleeve as shown in the figure. This operation must be carried out keeping the stem in a vertical position. Unscrew the cap. Using the key, adjust the spring pre- load adjuster while blocking the rotation of the nut pla- ced on the pump rod.
Page 229 Suspension and wheels Remove the spring-push spacer (1) and the relative spacer ring. Slide out the spring complete with the spacer. Remove the internal rod for the extension adjustment. - 17 -...
Page 230 Suspension and wheels Turn the stem upside down and completely pour out the oil into a suitable container. Recover the oil in an appropriate container. Do not dispose of the used oil in the envi- ronment. Unscrew the lower central screw that fixes the pump unit.
Page 231 Suspension and wheels Lower the anti-dust seal (1) taking care to not damage the seat on the sleeve. Remove the retaining ring (1) with a screwdriver, taking care to not scratch the stem. Extract the sleeve from the stem by repeated blows at the end.
Page 232 Suspension and wheels Unscrew the hydraulic braking adjuster under com- pression. Fork assembly check Check that the sleeve does not have marks on the external part that could have repercussions inside the assembly. Ensure that the inside is completely smooth, without any scratches.
Page 233 Suspension and wheels Assembly oil seal and anti-dust seal 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. Apply a "sleeve"...
Page 234 Suspension and wheels Reassemble the hydraulic brake adjuster under com- pression into its seat by utilising a new O-ring seal. Torque pressure of the compression hydrau- lic brake adjuster : 20 N•m 20 N•m Insert the internal rod. Insert the spring spacer. Maintain the sleeve in a vertical position.
Page 235 Suspension and wheels Check that the oil level is at an “X” value from the upper edge of the sleeve, including the upper edge as well. - BRUTALE 750 ORO / 750 S (MY 03): X = 90 mm - BRUTALE 750 S (MY 04): X = 85 mm - BRUTALE 910 S: X = 85 mm...
Page 236 Suspension and wheels Place the spring-push spacer (1) and the relative washer. 20 N•m Reassemble the complete cap with a new O-ring. Tighten the cap to the prescribed torque pressure. Stem cap torque pressure: 20 N•m Fork stem assembly Assemble the left stem in its seat. To position the stem correctly, refer to the diagram in the figure on the side.
Page 237 Suspension and wheels Tighten the three screws (1) at the base of the stee- ring; perform the operation several times until the pre- scribed torque pressure is reached. This operation must be carried for both stems. Torque pressure of the screws at the base of the steering: 8 ÷...
Page 238 Suspension and wheels Front suspension adjustment After having correctly reassembled the entire fork assembly, it is necessary to re-establish the adjust- ments shown in the table to guarantee the best set-up of the motorcycle. Carry out the same adjustment on both fork stems.
Page 239: Steering Assembly
Suspension and wheels STEERING ASSEMBLY 95÷100 (B4 750 ORO-S) N·m 18 ÷ 20 In contact + 10° Torque 120÷125 (B4 910 S-R) pressu- Kg·m ft·lb Operation - 27 -...
Page 240: Steering Assembly Overhaul
Suspension and wheels STEERING ASSEMBLY OVERHAUL To operate on the steering assembly, it is necessary to remove the fork stems as described in this chapter, in the paragraph “Front fork overhaul”. Then remove the components according to the following order: - front headlight;...
Page 241 Suspension and wheels Remove the screw ring previously slackened and remove the steering base complete with the pin. Remove the anti-dust seal, the internal bearing ring and the ball bearing ring. Eccentric steering head removal With the special tool remove the fixing screw ring of the eccentric steering head.
Page 242 Suspension and wheels Reassembly of the frame head steering sleeve Clean the parts accurately so that a visual check can be made of the tube and the seats. There should not be marks or lines in the bearing seats. If so, substitute the parts as necessary. Lightly grease the contact area of the frame head stee- ring sleeve (see figure) and the threaded part with Agip Grease 30.
Page 243 Suspension and wheels Screw ring assembly After having accurately cleaned the screw ring and the seat of the steering head on the frame, apply the pre- scribed grease both on the threading and on the coni- cal part of the screw ring, then screw it manually onto the relative seat.
Page 244 Suspension and wheels Assemble the steering base to the eccentric steering head. Assemble the upper ball bearing ring already greased. Assemble the internal ring of the bearing, the anti-dust sealand the screw ring of the steering pin. Steering pin tightening Screw down, without tightening, the screw ring of the steering pin.
Page 245: Rear Suspension
Suspension and wheels REAR SUSPENSION N·m 40 ÷ 44 40 ÷ 44 40 ÷ 44 50 ÷ 55 Torque Kg·m pressure ft·lb Operation Description BRUTALE 750 ORO BRUTALE 750 S BRUTALE 910 S BRUTALE 910 R REAR SUSPENSION Type Progressive with mono-arm fork and mono-shock absorber adjustable for extension, compression and spring preload Swingarm Magnesium alloy...
Page 246 Suspension and wheels Rear shock absorber disassembly Remove the fuel tank as described in chapter C “Bodywork”. Lift up the rear part of the motorcycle (utilising a lift and safety straps) high enough to take the load off the shock absorber. Slacken the upper screw of the shock absorber (1).
Page 247 Suspension and wheels Slacken the central fixing pin of the engine (5). Slacken the rear fork pin (6). These operations are necessary to free the compen- sator assembly. Lift up the compensator assembly. Remove the upper screw of the shock absorber that was previously slackened.
Page 248 Suspension and wheels Rear suspension adjustment The following operations can be also car- N.B. ried out with the rear shock absorber assembled to the motorcycle. Type of set-up (only rider) BRUTALE 750 ORO BRUTALE 750 S (MY 03) Soft Standard Hard Rebound damping 21 clicks...
Page 249 Suspension and wheels BRUTALE 910 S Type of set-up (only rider) (MY 07) Su strada In pista Rebound damping 14 clicks 10 clicks Compression damping 0 clicks 12 clicks (high speed) Compression damping 14 clicks 10 clicks (low speed) Type of set-up (with passenger) ** BRUTALE 910 S (MY 07) On road...
Page 250 Suspension and wheels 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. Check for eventual axial play of the bolt holes of the connecting rod (2).
Page 251 Suspension and wheels When reassembling, it is necessary to apply a special product to the three screws. Lightly screw them in. 40÷44 N•m Tighten the central screw first and then the other two to the prescribed torque pressure. Special product Loctite 243 Torque pressure: 40 ÷...
Page 252 Suspension and wheels Tighten up the whole assembly: Tighten the screws of the connecting rod. 40÷44 N•m 50÷55 N•m Tighten the lower and upper screw of the shock absorber. Tighten the frame pin (1). Tighten the swingarm pin (2). 55÷60 N•m Tighten the screw of the rocker arm assembly (3).
Page 253: Rear Wheel Hub And Swingarm
Suspension and wheels REAR WHEEL HUB AND SWINGARM Brutale 910 S - R N·m 30÷35 20÷22 45÷50 200÷220 28÷32 220÷240 140 25 25 70÷75 30÷35 18 18÷20 5÷7 Torque Kg·m pressure ft·lb Operation Description BRUTALE 750 ORO BRUTALE 750 S BRUTALE 910 S BRUTALE 910 R REAR WHEEL...
Page 254: Rear Wheel Removal
Suspension and wheels REAR WHEEL REMOVAL Before checking and overhauling the rear wheel hub assembly it is necessary to carry out the following pre- liminary operations: Place the motorcycle on the rear stand. Special tool N. 800092642 Remove the fixing screws of the lower silencer. Remove the exhaust protection.
Page 255 Suspension and wheels Remove the retaining ring (1) of the wheel nut. Remove the rear wheel by removing the polygonal nut, using the following tools: Torque wrench 55 mm polygonal spanner Utilising a torque wrench, slacken the rear wheel nut. The polygonal fixing nut of the rear wheel has a left hand thread.
Page 256 Suspension and wheels After having effectuated the rear wheel removal, sup- port the motorcycle with a lift as shown in the figure. Remove the rear stand. Remove the safety ring (1) of the crown flange-fixing nut. Slacken the nut of the flange by rotating it in an anti- clockwise direction as shown in the figure.
Page 257 Suspension and wheels Slacken the fixings (1) of the wheel hub. Remove the screw complete with bushing. Extract the chain guard by pulling it out from the back part of the wheel (see figure) so that it is freed from its position on the swingarm.
Page 258 Suspension and wheels Crown wheel assembly removal Brutale 750 ORO - S Remove the wheel spindle nut (2) previously slacke- ned and the spacer ring (4) underneath. Remove the crown wheel assembly (3) by manually pulling the assembly outwards. Make sure that a spacer ring is present between the flange and the hub.
Page 259 Suspension and wheels Slacken the two screws (6) and remove the brake cali- per (7). Disassembly of the wheel pin Remove the wheel spindle complete with the brake disc, extracting it from the right side of the motorcycle as shown in the figure. Brake caliper support flange removal Remove the Seeger retaining ring (1), the spacer ring (2), the flange (3) and the spacer ring underneath.
Page 260 Suspension and wheels Wheel hub disassembly Extract the wheel hub from the left side of the fork. Carefully wash all parts. Check the condition of the roller bearing and the ball bearing. If there is excessive play (even only one of the bea- rings) or chamferings during rotation, substitute the wheel hub, complete with bearings with a new unit.
Page 261: Swingarm Removal And Overhaul
Suspension and wheels SWINGARM REMOVAL AND OVERHAUL Before removing and overhauling the swingarm, it is necessary to execute the following preliminary opera- tions: - Remove the rear shock absorber and connecting rod as described in the paragraph “Disassembly rear shock absorber” and “rocker arm assembly removal” of this chapter.
Page 262 Suspension and wheels Unscrew the screw fixing the silencers to the support. Remove the upper silencer first, then the lower one. Remove the other components of the rear wheel assembly as shown in the operations previously described from page 41. Exhaust group removal (Brutale 750 ORO-S / Brutale 910 S-R MY 05/06) Unhook the two connecting springs between the silen-...
Page 263 Suspension and wheels Unscrew the screw fixing the compensator to the frame. Unscrew the pin from the left side of the frame, then remove the exhaust compensator. Discharge system dismantling (910 S-R MY 2007) Disconnect the lambda probe connector from the main cabling and pull outwards, on the right side of the vehi- cle.
Page 264 Suspension and wheels Unscrew the lower fixing screws of the oil radiator guard, positioned at the lower base of the water radia- tor. Remove the oil radiator guard. Move the radiators slightly towards the front of the motorcycle, then remove the flange fixing the exhaust manifolds to the cylinder unit by unscrewing the nut.
Page 265 Suspension and wheels Unscrew the pin from the left side of the housing. Remove the exhaust manifolds by turning slightly towards the right of the vehicle. Lower chain guide removal Remove the three screws of the chain guide. Remove the chain guide (1) complete with the two rear brake tube guide plates.
Page 266: Chain Removal
Suspension and wheels CHAIN REMOVAL Remove the chain utilising the special tool. Special tool N. 800095389. Identify the connecting link. The core section of the tool should act on the internal part of the chain. N.B. The tool has three functions: •...
Page 267: Chain Reassembling
Suspension and wheels CHAIN REASSEMBLING 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 268 Suspension and wheels Mount the tool onto the chain as shown in the figure and align the punch on «A». 30÷35 N•m Manually tighten the screws until contact is felt with the backing plate. Tighten at the specified torque. Connecting link plate press fitting torque pressure: 30 ÷...
Page 269 Suspension and wheels Swingarm pin removal Remove the screw (1) on the right side of the motorcy- cle. Remove the washer and push out the pin manually. Support the swingarm so that it does not drop to the ground. Now the swingarm can be extracted. Upper chain guide removal Remove the two screws (1) and the relative plates.
Page 270 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 271 Suspension and wheels Extract the spacer from the right side. Check the condition of both bearing seats and the seat of the spacer. If the spacer is in good condition, reinsert it onto the fork from the right side. Assembly of the roller bearings and the roller bea- ring units Pre-assemble the two roller bearing units on the left side and the two ball bearings on the right hand side...
Page 272 Suspension and wheels Wheel spindle unit check Check the condition of the wheel drive engagement splines. If it is worn, substitute as follows. After heating with a heat gun, remove the four fixing screws (1) of the brake disk flange sealed with Loctite 270.
Page 273 Suspension and wheels Utilising a press with an adequate punch for both the removal and assembly of the pins of the wheel drive engagement. When assembling, apply force on the crown of the peg not on the point. (see figure). Assemble the brake disc carrier plate by tightening the screws to the prescribed torque pressure and then apply Loctite 270.
Page 274 Suspension and wheels Crown wheel assembly check (Brutale 910 S - 910 R) Evaluate the wear condition of the crown wheel. If it is badly worn, effectuate a substitution with a new part. Push the crown support of the flange unit (1) out from the crown unit (2).
Page 275 Suspension and wheels When reassembling the crown unit to the crown sup- port flange unit, grease the coupling areas. Grease used: AGIP GR SM Do not apply grease to the threads of the pins. Reassembly wheel hub Lightly grease the wheel hub. Introduce the hub to the swingarm from the left side of the motorcycle and push it in.
Page 276 Suspension and wheels Introduce the first spacer. Grease and insert the roller bearing unit. Assemble the second spacer (the ground one). The grease used must have the following characteristics: – Lithium soap grease with a mineral oil base – Consistency NLGI: 2 –...
Page 277 Suspension and wheels Insert the spacer ring illustrated in the figure onto the wheel pin. Insert the crown wheel assembly, the second spacer ring and the wheel pin fixing nut. Reassemble the chain as described at page 52 of this chapter.
Page 278 Suspension and wheels Rear wheel assembly In the case of substitution of the rear tyre it will be necessary to effectuate the balancing of the wheel before assembling it. Follow the instructions indicated in page 69. Insert 1st gear. Reassemble the rear wheel. Tighten the wheel axis nut to the prescribed torque pressure.
Page 279 Suspension and wheels 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. Straighten the metal tongue with a flat-head drift and hammer.
Page 280 Suspension and wheels For reassembly, insert the pinion wheel with the chain already attached. Insert a new washer on to the threaded cam shaft, tigh- ten the nut and strongly tighten the prescribed coupling using an average-strength threadlock fluid. Hammer the new washer down onto the two opposite faces of the hexagon.
Page 281: Motorcycle Set-Up Adjustment
Suspension and wheels MOTORCYCLE SET-UP ADJUSTMENT Place the motorcycle on the rear stand. Special tool N. 800092642 WARNING: The following adjustments must be performed when the fuel tank is full. Insert the setting-up arm (A) of the rear suspension (special tool) in its appropriate seats as shown in the figure.
Page 282 Suspension and wheels Using a ring spanner, adjust the half connecting rod distancing by regulator (1) until the required X1 level is reached. Tighten the fixing screws of the semi-connecting rods to the prescribed torque pressure. Torque pressure: 8÷10 N•m 8÷10 N•m Press down on the seat so that the shock absorber is compressed and then let it go back into its resting posi-...
Page 283 Suspension and wheels Measure the distance X between the upper extremity of the rear stand tube and the point on the setting-up arm indicated by the arrow in the figure. Δ Calculate the static slack according to this formula: Δ 1 –...
Page 284: Wheel Balance Check
Suspension and wheels At the end of the spring adjustment operation, tighten the upper lock ring as shown in the figure. After having completed the adjustment of the motorcy- cle set-up, it is necessary to adjust the tension of the chain.
Page 285 Suspension and wheels Rear wheel balancing Before mounting the rear wheel on the appropriate tool, insert the balancing tool into the central hole of the wheel. Special tool N. 800092865 Insert the polygonal nut of the balancing tool from the opposite side and screw it onto the threaded part of the tool so that the tool can be fixed to the wheel.
Page 286 Suspension and wheels Place the dial gauge as shown in the figure, and check the flatness. Flatness must not exceed: 0.5 mm. When effectuating balancing on certain makes of tyres, it is necessary to refer to the yellow mark (1) present on the side of the tyre as shown in the figure.
Page 287: Frame
Frame SECTION Revision 2 - 1 -...
Page 288 Frame SUMMARY FRAME REMOVAL PRELIMINARY OPERATIONS ........PAGE 3 THROTTLE BODY REMOVAL .
Page 289: Frame Removal Preliminary Operations
Frame FRAME REMOVAL PRELIMINARY OPERATIONS Place the motorcycle on the rear stand no. 800092642. Operating on the right side, remove the sealing cover by unscrewing the two fixing nuts. Operate in the same way to remove the left sealing cover. Remove the components in the following sequence: - Passenger and rider seat;...
Page 290 Frame Utilising the lift no. 800095807 equipped with the pin no. 800095808, lift up the front part of the motorcycle. Remove the components in the following sequence: - Front mudguard; - Front brake calipers; - Front wheel; - Water radiator; the procedure for removing the components indicated are described in chapter F “Suspensions and wheels”, chapter H “Brakes”...
Page 291 Frame Remove the two fixing screws (1) of the front headlight on the sides. Take care to slide the adjuster out of its seat when the headlight is removed from the support. Before removing the front headlight, disconnect the connector (2) placed in the rear part of the headlight. Then remove the headlight support and the instrument panel as described in chapter C “Bodywork”.
Page 292 Frame Protect the area around the fluid chamber with a cloth or paper. Remove the union and discharge the clutch fluid from the system into an appropriate container. Remove the steering assembly and the relative com- ponents of the front suspension as described in chap- ter F “Suspensions and wheels”.
Page 293: Throttle Body Removal
Frame THROTTLE BODY REMOVAL Slacken the nut (1) fixing the accelerator control wiring to the support plate of the throttle body. Fleet the accelerator control wiring and extract the pawl (A) of the opening wiring. Carry out the same operation on the pawl of the closing wiring.
Page 294 Frame Slacken the bands (1) fixing the throttle body to the air intake of each cylinder. Disconnect the connections relative to the injectors of each cylinder. Remove the complete throttle body assembly. - 8 -...
Page 295: Coil Dismantling (Brutale 750 Oro - S / Brutale 910 S-R My 05-06)
Frame Extract the connectors from the coils. To carry out this operation, free the secondary lock (yellow "tongue") by extracting it from its seat, then press the black "tongue" and unhook the connector. Unscrew the earth connection on the engine head cover and free the coil wiring from the frame by remo- ving the two fixing bands;...
Page 296 Frame Unscrew and remove the coil backing plate fixing screws (1). Remove the coils from their housings. Operating on the right side of the motorcycle unscrew and remove the two fixing screws of the rear sealing protection, then free the protection. Operate on the left side to remove the left rear sealing protection.
Page 297: Secondary Air System Dismantling (Brutale 910 S-R My 2007)
Frame SECONDARY AIR SYSTEM DISMANTLING (BRUTALE 910 S-R MY 2007) Disconnect the connector (1) from the secondary air unit. Disconnect the secondary air hoses (1) and (2) to the cylinders by loosening the clamps. Disconnect the airbox connector hose (1). - 11 -...
Page 298 Frame Unscrew the screws (1) and remove the fixing plate (2). Remove the two CLIC R 96105 clamps using special pliers. Remove the two rubber bands so to free the wiring from the frame. - 12 -...
Page 299 Frame Slide the CPU out from the fixing support fixed to the frame. Slide out the main wiring and fold it backwards on the rear sub-frame. Fix the main wiring to the sub-frame with an elastic band. - 13 -...
Page 300: Frame Disassembly
Frame FRAME DISASSEMBLY Operating in the same way on both sides of the motorcycle unscrew and remove the front screw fixing the engine cylinder head to the frame and collect the eccentric washer. Operating on the right side unscrew and remove the rear nut fixing the engine assembly to the frame.
Page 301 Frame Remove the screws fixing the frame tothe union plates from both sides. Remove the frame rotating the steering head housing upwards. Frame check Accurately clean the conical seats of the steering head housing. - 15 -...
Page 302 Frame Check that there are no marks or signs on all surfaces. Check that the area shown in the figure is not defor- med (as a consequence of accident damage). Check that there are marks of evident breakages along the frame tubes. If damage is found, substitute the frame.
Page 303 Frame - 17 -...
Page 304: Frame Control Reference Measurements
Frame FRAME CONTROL REFERENCE MEASUREMENTS To carry out a detailed check of the frame, herewith below are the reference measurements that are of fun- damental importance for the correct condition of the frame. - 18 -...
Page 305 Frame Steering head housing check Check the diameter and eventual ovalisation of the 5 mm steering head housing, 5 mm from the lip of the bevel- ling as shown in the figure. Measure the ovalisation in diverse points as shown in the figure.
Page 306: Assembly Frame To The Motorcycle
For the stamping and the homologation labels of the new frame, contact the MV AGUSTA service centre. Thoroughly clean the matching surfaces of the frame- engine cylinder head and frame-union plates.
Page 307 With regards to the positioning of the cables, fasteners and various wiring consult the various tables shown in the F4 Brutale 750 ORO - 750 S Spare Parts Catalogue (Code 800099359) - 910 S - 910 R Spare Parts Catalogue (Code 8000A5273).
Page 308 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 309 Frame - 23 -...
Page 310: Rear Sub-Frame Removal
Frame REAR SUB-FRAME REMOVAL After having carried out the removal of all the neces- sary components described in the previous paragraph, remove the connector (1) on the generator. Unscrew and remove the nut fixing the generator wiring to the system. Unscrew and remove the nut fixing the starter motor wiring to the starter switch.
Page 311 Frame Unscrew and remove the screw fixing the engine earth cable to the fixing support of the rear brake fluid tank. Once the wiring has been freed and collected as shown in the figure, it is possible to remove the rear sub-frame.
Page 312 Frame At this point it is possible to remove the complete sub-frame assembly from the motorcycle. Rear frame unit assembly Carry out the operation of reassembling the rear sub- frame on the motorcycle in the reverse order of remo- val, taking care to tighten the fixing screws to the pre- scribed torque pressure.
Page 313: Engine Removal
Frame ENGINE REMOVAL Side stand removal Operating on the left side of the motorcycle, unscrew and remove the two fixing screws of the side stand switch. Disconnect the connector of the side stand switch from the main wiring. Disconnect the connector of the speed sensor (1) from the main wiring.
Page 314 Frame Remove the side stand assembly by unscrewing the three fixing screws (1). Slide the terminals of the connections out of fixing sup- port. Gearchange lever removal Unscrew the fixing screw (1) and slide out the gear- change lever (2). - 28 -...
Page 315 Frame Operating on the right side of the motorcycle, remove the fixing support of the rear brake fluid tank by unscrewing the fixing screw (1). Remove the rear brake pump and the relative protec- tion as described in chapter H “Brakes”. The figures show the collectors when N.B.
Page 316 Frame DISCHARGE SYSTEM DISMANTLING (BRUTALE 750 ORO-S / BRUTALE 910 S-R MY 05/06) Remove the exhaust collectors fixing flanges of the cylinders 1-2-3-4 by unscrewing the fixing nuts. Unhook the union spring between the compensator and the collector of cylinders 3-4. Remove the collector of cylinders 3-4 by sliding it out of the primary compensator.
Page 317 Frame Unhook the union spring between the compensator and the collector of cylinders 1-2 and remove the col- lector by sliding it out of the primary compensator. Unhook the two connecting springs between the exhaust group and the silencers. Remove the connecting plate between the two silen- cers.
Page 318 Frame Unscrew the screw fixing the silencers to the support. Remove the upper silencer first, then the lower one. Unscrew the screw fixing the compensator to the frame. - 32 -...
Page 319 Frame Remove the exhaust compensator by removing it from the pin on the left side of the frame. Discharge system dismantling (910 S-R MY 2007) Disconnect the lambda probe connector from the main cabling and pull outwards, on the right side of the vehi- cle.
Page 320 Frame Move the radiators slightly towards the front of the motorcycle, then remove the flange fixing the exhaust manifolds to the cylinder unit by unscrewing the nut. During this operation, take care near the discharge hoses in order to avoid scalding. Unscrew the compensatory housing fixing screws.
Page 321 Frame Remove the exhaust manifolds by turning slightly towards the right of the vehicle. Remove the chain as described in chapter F “Suspensions and wheels”. Position an appropriate lift to support the rear suspen- sion/fork assembly as shown in the figure. - 35 -...
Page 322 Frame Slacken the fixing screw of the front fork pin by 1 turn. Slacken the nut on the rear suspension compensator pin. Remove the engine support lower pin fixing nut. - 36 -...
Page 323 Frame Operating on the left side extract the engine support pin. Extract the bush shown in the figure from the union pla- tes of the frame from both sides. Remove the engine assembly from the union plates by dragging it forwards. - 37 -...
Page 324 Frame Operating on the right side, remove the fork pin fixing screw (1) taking care to recuperate the washer (2). Recuperate the spacer. The spacer is present on the Brutale ORO N.B. model only. Remove the right union plate. Remove the rear suspension pin fixing nut and slide out the pin from the left side.
Page 325 Frame Remove the fork pin (1) and the spacer (2). The spacer is present on the Brutale ORO N.B. model only. Remove the left union plate. When reassembling proceed in the reverse order of removal, taking care to apply the prescribed grease and to tighten every fixing to the torque pressure indi- cated on page 20 of this chapter.
Page 326 Frame - 40 -...
Page 327: Brakes
Brakes SECTION Revision 2 - 1 -...
Page 328 Brakes SUMMARY FRONT BRAKE SYSTEM ............PAGE 3 FRONT MUDGUARD REMOVAL .
Page 329: Front Brake System
Brakes FRONT BRAKE SYSTEM N•m 15 ÷ 20 23 ÷ 25 38 ÷ 42 16 ÷ 18 16 ÷ 18 8 ÷ 10 23 ÷ 26 42 ÷ 46 Torque Kg•m pressure ft•lb Operation Description BRUTALE 750 ORO BRUTALE 750 S BRUTALE 910 S BRUTALE 910 R FRONT BRAKE...
Page 330: Front Mudguard Removal
Brakes FRONT MUDGUARD REMOVAL Remove the four screws of the rear attachment of the front mudguard as shown in the figure (the two lower screws are mounted with a bush). Remove the front brake tubing from the clip mounted on the attachment. Widen the attachment and slide it out of its seat.
Page 331 Brakes Unscrew the pad support pin as indicated in the figure. Compress the spring and extract the pin. Remove the pads. Every 6000 kilometres, check the wear of the pads. Front brake caliper The pad thickness must not be less than 1 mm. If the pads are excessively worn, substitute them.
Page 332: Front Brake Pads Substitution (Brutale 910 R)
Brakes To effectuate the assembly of the new pads, align the holes of the pads with the holes in the caliper. After having visually checked the condition of the pad plates, check that they offer sufficient pressure to the pad during the assembly phase. Check the condition of the pad-retaining threaded pin.
Page 333 Brakes Compress the spring and extract the pin. Remove the two springs, the two pins and the four pads. Every 6000 kilometres, check the wear of the pads. Front brake caliper The pad thickness must not be less than 1 mm. If the pads are excessively worn, substitute them.
Page 334: Substitution And Bleeding Of The Front Brake Fluid
Brakes When refitting, push the pads all the way in. Insert the spring and, while pressing it down, insert the pin. Ensure that the spring is properly seated by pulling it outwards as shown in the figure. SUBSTITUTION AND BLEEDING OF THE FRONT BRAKE FLUID Place the motorcycle on a horizontal surface with the steering in a straight line.
Page 335 Brakes Remove the protection cap of the bleed valve of the front right caliper. Apply a rubber tube to the bleed valve (the valve is pla- ced on the summit of the brake pincer). Put the other end of the rubber tube in a suitable con- tainer.
Page 336 Brakes Tighten the bleed screw, remove the rubber tube, care- fully clean the screw with alcohol, blow it dry and put the protective cap back on. Bleed screw tightening torque: - B4 750 ORO / 750 S / 910 S: 8 Nm - B4 910 R: 6 Nm Using circlip pliers, slowly widen the brake pads in their respective seats so that it avoids the emulsion of the...
Page 337 Brakes Top-up the level of the fluid until it reaches the maxi- mum mark. Carefully clean around the edge of the brake fluid chamber utilising a clean cloth. Imperfect cleaning of this component could cause the loss of small quantities of brake fluid whilst riding.
Page 338: Front Brake Calipers Substitution (Brutale 750 Oro - 750 S - 910 S)
Brakes Place the cap on the brake fluid chamber and tighten the two lateral fixing screws. FRONT BRAKE CALIPERS SUBSTITUTION (BRUTALE 750 ORO - 750 S - 910 S) • It is advisable to remove the brake pads to facilitate the operation.
Page 339: Front Brake Calipers Substitution (Brutale 910 R)
Brakes FRONT BRAKE CALIPERS SUBSTITUTION (BRUTALE 910 R) • It is advisable to remove the brake pads to facilitate the operation. • Slightly move the front brake lever towards the right handgrip and hold it in position with a strap to limit the outflow of brake fluid during subsequent opera- tions.
Page 340 Brakes Remove the union indicated in the figure. 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. - 14 -...
Page 341: Front Brake Lever Removal
Brakes To substitute the front brake switch remove the screw shown in the figure. After having carried out the overhaul of the front brake pump assembly, carefully wash and bleed the front brake system as previou- sly described in this chapter. FRONT BRAKE LEVER REMOVAL Unscrew the blocking nut.
Page 342: Clutch Lever Removal
Brakes When reassembling take care to insert the lever into its seat. 8÷10 N•m Grease the pin with the specified product. Recommended grease: Agip Grease 30 Insert the pin into the seat and screw it in until the beat is reached, then tighten the nut by using a screwdriver. Front brake lever nut torque pressure: 8 ÷...
Page 343: Front Brake Discs
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 with the specified product. Recommended grease: Agip Grease 30 For the reassembly of the lever tighten the pin. Keeping the pin still, tighten the nut with a screwdriver.
Page 344: Front Brake Discs Removal
Brakes FRONT BRAKE DISC REMOVAL Remove the front wheel from the motorcycle (see paragraph “Front brake caliper removal”). Remove the front wheel pin utilising two special tools (see chapter F “Suspensions and wheels”). Special tool 800092872 Place the wheel in a horizontal position on a work plane and remove the five screws of each disc procee- ding in a star-like mode for the removal.
Page 345 Brakes Front disc assembly Thoroughly clean the contact surfaces of the discs and the wheel. Accurately grease all relative surfaces of the disc befo- re reassembling. Apply thread-locking fluid to the five fixing screws of the disc. Recommended thread-locking fluid: Loctite 243 Screw in the screws lightly, proceeding in a star-like mode.
Page 346: Rear Brake System
Brakes REAR BRAKE SYSTEM N•m 220 ÷ 240 15 ÷ 20 16 ÷ 18 16 ÷ 18 18 ÷ 20 Torque Kg•m pressure ft•lb Operation Description BRUTALE 750 ORO BRUTALE 750 S BRUTALE 910 S BRUTALE 910 R REAR BRAKE Type Steel disc Ø...
Page 347: Rear Brake Pads Substitution
Brakes REAR BRAKE PADS SUBSTITUTION Place the motorcycle on the rear stand. Special tool N. 800092642 Remove the fixing screws of the lower silencer. Remove the exhaust protection. Turn the lower silencer outwards slightly. If this movement is difficult due to residue in the com- pensator connection area, clean the part by applying lubricant/penetrating spray.
Page 348 Brakes Remove the retaining ring of the wheel nut. Remove the rear wheel by removing the polygonal nut, using the following tools: Torque wrench 55 mm polygonal spanner Utilising a torque wrench, slacken the rear wheel nut. The rear wheel blocking nut has a left-hand thread, so to loosen the rear wheel blocking nut it must be turned clockwise.
Page 349 Brakes Utilising circlip pincers as shown in the figure, widen the pads so that the pistons are pushed back into their seats. The outward movement of the brake pads provocates the retraction of the pistons in their relative seats, with a consequent increase in the level of the brake fluid in the brake fluid chamber.
Page 350: Substitution And Bleeding Of The Rear Brake Fluid
Brakes Analyse the condition of the rear brake system and its components. Proceed with the reassembly in the reverse order of removal. Tighten the pin to the prescribed torque pressure. Rear brake caliper pin torque pressure: 15 ÷ 20 N•m 15÷20 N•m SUBSTITUTION AND BLEEDING OF THE REAR BRAKE FLUID...
Page 351 Brakes Open the cover of the rear brake fluid reservoir by removing the two screws. To substitute the brake fluid, connect a rubber tube to the bleed valve, then empty the system in an appro- priate container by slackening the bleed screw as shown in the figure while keeping the brake lever pushed.
Page 352: Rear Brake Caliper Substitution
Brakes Before closing the fluid reservoir, check the condition of the components. REAR BRAKE CALIPER SUBSTITUTION To facilitate the operation, remove the brake pads as described previously. Remove the crown wheel as described in chapter F “SUSPENSIONS AND WHEELS”. Empty the system of brake fluid as described in para- graph “Substitution and bleeding of the rear brake fluid”.
Page 353 Brakes Assemble the union tightening to the prescribed tor- que. 16÷18 N•m Torque pressure: 16 ÷18 N•m Substitute the washers with new ones. N.B. If the brake pads have been removed, reassemble them. Proceed with the filling and bleeding of the rear brake system (see page 24).
Page 354: Rear Brake Disc
Brakes Unscrew the two fixing screws of the brake pump to its relative support. Remove the pump. After having carried out a check on all components and substituted those used, damaged or defective proceed 16÷18 N•m 8÷10 N•m with the assembly by following the procedure in rever- se order of removal.
Page 355: Rear Brake Disc Removal
Brakes REAR BRAKE DISC REMOVAL Before proceeding with the removal of the rear brake disc, it is necessary to carry out certain operations described previously in this chapter: Remove the rear wheel. Remove the rear brake disc from its support. Remove the four nuts fixing the disc to the flange spli- ned to the wheel pin.
Page 356 Brakes Before reassembling the rear brake disc, check the condition of the four pins and four special nuts. 18÷20 N•m Proceed with tightening of the nuts. The screws must be assembled with the nuts screwed in lightly and brought into con- tact with the disc surface.
Page 357: Cooling System And Lubrication System
Cooling system and lubrication system SECTION Revision 3 - 1 -...
Page 358 Cooling system and lubrication system SUMMARY COMPLETE COOLING SYSTEM ASSEMBLY AND LUBRICATION SYSTEM...........PAGE 3 COOLING SYSTEM LEAKAGE CHECK ....................PAGE 4 EXPANSION TANK CAP CHECK ......................PAGE 4 ENGINE COOLANT EXTRACTION......................PAGE 5 EXPANSION TANK REMOVAL .........................PAGE 5 DISASSEMBLING WATER RADIATOR ....................PAGE 8 COOLING FAN DISMANTLING (BRUTALE 750 ORO - S / 910 S - R MY 05/06) ........PAGE 12 COOLING FAN DISMANTLING (BRUTALE 910 S-R MY 2007) ............PAGE 13 CHECKING COOLING FAN STARTER.....................PAGE 15...
Page 359: Complete Cooling System Assembly And Lubrication System
Cooling system and lubrication system COMPLETE COOLING SYSTEM ASSEMBLY AND LUBRICATION SYSTEM Before checking, disposing of, or overhauling any component relevant to the cooling and lubrication perform some preliminary operations system: 1) Let the engine cool down. 2) Remove the passenger and pilot seat, right and left side panel, ignition switch cover, fuel tank and air filter com- partment as described in the chapter C “Superstructures”.
Page 360: Cooling System Leakage Check
Cooling system and lubrication system COOLING SYSTEM LEAKAGE CHECK Before removing the radiator and discharging the engi- ne coolant, check that the cooling system does not have leakages. Remove the expansion tank cap and connect the tester (of the type shown in the diagram) to the filler hole.
Page 361: Engine Coolant Extraction
Cooling system and lubrication system ENGINE COOLANT EXTRACTION Remove the ignition commutator cover unscrewing the two fixing screws (1). Open the cap of the expansion tank (2). Empty the cooling system of the coolant as follows: • Place under the engine a container to collect the discharged coolant;...
Page 362 Cooling system and lubrication system Disconnect the connector (1) of the ignition switch and remove the relative rubber clamp (2) by working on the right side of the vehicle. On the right side of the motorcycle remove the clamp (1) connecting water radiator breather pipe to the expansion tank using specific pliers CLIC R 205 and its rubber clamp (2).
Page 363 Cooling system and lubrication system In order to extract the pipe you should release it from the fixing point shown by the arrow in the figure on the side. Remove the ignition switch support unscrewing the four screws (1). On the left side of the motorcycle remove the clamp (1) connecting the water radiator charging pipe to the expansion tank using a specific pliers CLIC R 205 and its rubber clamp placed near the fluid supply tank.
Page 364: Disassembling Water Radiator
Cooling system and lubrication system DISASSEMBLING WATER RADIATOR Remove the upper (1) and side (2) protections of the water radiator unscrewing the respective fixing screws on both sides of the radiator. Remove the oil radiator protective guard (1) by unscrewing the two fixing screws. Remove the upper plastic protection (1) unscrewing the two fixing screws.
Page 365 Cooling system and lubrication system Remove the protective grid (1) taking it out from its seat. Disconnect the connector (1) of the water radiator elec- tric fan on the right side of the motorcycle. For Brutale 910 S – 910 R (MY2007) models only: Disconnect the two water radiator cooling fan connectors (1) located on the right side of the...
Page 366 Cooling system and lubrication system Disconnect the connector (1) of the water temperature sensor to the instrumentation panel on the left side of the motorcycle. Remove the clamp (1) on the water suction pipe cou- pling from the pump to the radiator using the specific pliers CLIC R 205.
Page 367 Cooling system and lubrication system Disconnect the fixing link rod on the right side of the water radiator. Move the radiator towards the front side of the motorcycle in order to the release the water suction pipe coupling (1) from the pump to the radiator. Release the water inlet pipe coupling to the radiator (1) to the radiator from the thermostat valve.
Page 368: Cooling Fan Dismantling (Brutale 750 Oro - S / 910 S-R My 05/06)
Cooling system and lubrication system Remove the radiator fixing screws on the left side of the motorcycle. Remove the radiator moving it right in order to release it from the peg (A) on the frame support. COOLING FAN DISMANTLING (BRUTALE 750 ORO - S / 910 S-R MY 05/06) Unscrew the three screws (1) and remove the comple- te fan support.
Page 369: Cooling Fan Dismantling (Brutale 910 S-Rmy 2007)
Cooling system and lubrication system For replacing fan you should remove the three nuts (1) for fixing fan (2) and protecting (3) the support (4). COOLING FAN DISMANTLING (BRUTALE 910 S-R MY 2007) Remove the rubber clamp and free the cabling from the right and left sides of the fan units.
Page 370 Cooling system and lubrication system Unscrew the three screws (1) and remove both the fan unit and support. Remove the clamp connecting the cooling fan to the support. Before replacing the fan it is important to remove the three blocking nuts (1) from the fan (2) and the guard (3) attached to the support (4).
Page 371: Checking Cooling Fan Starter
Cooling system and lubrication system CHECKING COOLING FAN STARTER In order to verify the efficiency of the electric fan star- Ampmeter Motorino ter, this starter must be connected as shown in the figu- Fan motor elettroventola Amperometro re by using voltmeter and amperometer. During the test the starter must be powered.
Page 372: Cooling Fan Reassembly (Brutale 910 S-Rmy 2007)
Cooling system and lubrication system Ensure that the protective sheath (2) is inserted on the fan wiring. Position the wiring of the upper electric cooling fan as indicated in the figure. Insert the electrical connector into its tongue support in the area indicated of the fan frame and fix the cable using the appropriate tear clamps (1) as shown in the figure.
Page 373 Cooling system and lubrication system Measure the minimum span between the fan and radiator pack using a feeler gauge as illustrated in the diagram. Perform the measurement several times in the mini- mum span area around the entire fan. The minimum distance “d” must be in the following dimensional range: 1.5 <...
Page 374 Cooling system and lubrication system Fit the left fan unit cabling to the related support using a pull clamp. Fit the right fan unit cable connector to the special plate on the right fan support. Position the right fan unit cabling as shown in the dia- gram and fit to the related support using a pull clamp.
Page 375 Cooling system and lubrication system Fit the right and left fan unit cabling using rubber clam- FLUID TEMPERATURE SENSOR (BRUTALE 750 ORO-S / 910 S-R MY 05/06) If necessary, check the efficiency of the liquid tempe- rature sensor by removing it from the radiator. Remove the temperature sensor of the cooling liquid using a 19 mm wrench.
Page 376: Coolant Temperature Sensor (Brutale 750 Oro - S / 910 S - R My 05/06)
Cooling system and lubrication system Temperature Average resistance 20 °C Approx. 3,747 Kohm 50 °C Approx. 1,150 Kohm 80 °C Approx. 0,377 Kohm 110 °C Approx. 0,153 Kohm 125 °C Approx. 0,102 Kohm If the resistance is infinite or quite different from those indicated, the coolant temperature sensor must be substituted.
Page 377 Cooling system and lubrication system Remove the cover of the thermostat (1). Remove the thermostat (2). Checking thermostat valve Check to see if the thermostat pad is damaged. Check the functioning of the thermostat as follows: • Suspend the thermostat by a piece of string threa- ded through the flange as indicated in the figure.
Page 378: Reassembling Thermostat Valve
Cooling system and lubrication system REASSEMBLING THERMOSTAT VALVE Insert the O-ring (1) in its appropriate seat on the cover of the thermostat. Check the condition of the O-ring previously utilised. If the O-ring is not in good condition, substi- tute it with a new one. Apply a thin layer of silicone grease.
Page 379 Cooling system and lubrication system Insert the cover of the thermostat, complete with ther- mostat onto the engine. 10 N•m Tighten the three fixing screws (1) to the prescribed torque pressure. Torque pressure: 10 N•m If the water temperature sensor connector was remo- ved previously, the following action must be taken.
Page 380 Cooling system and lubrication system For Brutale 910 S – 910 R (MY2007) models only: Connect the water temperature sensor electrical cable (1) to the control unit. Block the water temperature sensor electrical cable with an elastic clamp as illustrated in the diagram. - 24 -...
Page 381: Reassembling Expansion Tank
Cooling system and lubrication system REASSEMBLING EXPANSION TANK Position the tube in respect of the expansion tank as indicated in the figure. Position the expansion tank on the frame; if the opera- tion is difficult, slightly turn the tank clockwise. Insert the radiator water breather pipe (1) and the over- flow pipe (2) inside the seats on the plastic clip (3).
Page 382 Cooling system and lubrication system If the “overflow” tube was previously removed, reposi- tion it and fasten with the three rubber clamps (1) as shown in the figure. Ensure that the placement follows the figure and inclu- des also the clutch control piping (2). Put the overflow pipe (1) on the nozzle of the expan- sion tank cap (2) again, until it reaches the reference limit shown in the figure.
Page 383: Assembling Water Radiator
Cooling system and lubrication system On the left side of the motorcycle, insert the water radiator connecting pipe (2) to the expansion tank. Secure it using a clamp (1) CLIC R 205 with relevant specific pliers. Specific tool CLIC R 205 Reconnect the connector (1) with the main wiring con- nection.
Page 384 Cooling system and lubrication system On the left side of the motorcycle insert the radiator fixing screw and tighten it to the prescribed torque 10 N•m wrench. Torque wrench setting of the radiator fixing screw: 10 N•m Insert the delivery pipe coupling that connects the ther- mostat valve with the radiator.
Page 385 Cooling system and lubrication system On the right side of the motorcycle connect the electric fan connector (1) with the main wiring. For Brutale 910 S – 910 R (MY2007) models only: On the right side of the vehicle, connect the cooling fan connectors (1) to the main cabling connection.
Page 386 Cooling system and lubrication system Insert the protective grid (1) working from the bottom upwards. Assemble the plastic upper protection (1) and secure it using the two fixing screws. Assemble the side (2) and upper (1) protections secu- ring them on the radiator using the respective fixing screws.
Page 387 Cooling system and lubrication system Perform the same operation for assembling the oil radiator protection. Fill the system using the appropriate fluid. Fill until a level slightly over the notch indicating the MIN level is reached. Tighten the sealing cap of the expansion tank. - 31 -...
Page 388 Cooling system and lubrication system For assembling repeat the same phases described for disassembling the components, but reversing the order. Reassemble the following components in order: - Air filter compartment - Fuel tank Start the engine for a few seconds. Let it cool and then re-check the level of the cooling liquid inside the expansion tank.
Page 389: Removing Oil Radiator
Cooling system and lubrication system REMOVING OIL RADIATOR Before removing the oil radiator you should completely drain the lubrication system. Put an appropriate vessel under the engine. Remove the oil drain plug (1). Recover the coolant in an appropriate vessel. Do not drain liquid into the environment.
Page 390 Cooling system and lubrication system For Brutale 750 ORO-S / Brutale 910 S-R MY 05/06 models only: Remove the exhaust manifolds of the cylinders 1-2-3- 4 unscrewing the fixing nuts of the fixing flange (1) from the cylinders. During this operation pay attention to the exhaust pipes in order to avoid scorching if the engine is still hot.
Page 391 Cooling system and lubrication system For Brutale 910 S – 910 R (2007) models only: Disconnect the lambda probe connector from the main cabling and pull outwards, on the right side of the vehi- cle. Move the radiators slightly towards the front of the motorcycle, then remove the flange fixing the exhaust manifolds to the cylinder unit by unscrewing the nut.
Page 392 Cooling system and lubrication system Unscrew the pin from the left side of the housing. Remove the exhaust manifolds by turning slightly towards the right of the vehicle. Only if it is necessary replacing the oil radia- tor, perform the following operation. Remove the oil delivery and return pipings connected with the oil radiator unscrewing the fixing nuts.
Page 393 Cooling system and lubrication system Remove the engine/ radiator support fixing screw pla- ced on the left side. This figure and the next ones show an N.B. engine assembly which the water radiator has been removed from; but the described operations can be performed also when the radiator is assembled.
Page 394: Reassembling Oil Radiator
Cooling system and lubrication system REASSEMBLING OIL RADIATOR Insert the support peg in the support (1) on the right side making the oil radiator move from left to right. Connect the engine/radiator anchor rod (1) on the left side. Put the radiator/engine support on the left side again and secure it tightening the screw.
Page 395 Cooling system and lubrication system If pipings and unions had been removed from the radiator, reassemble carefully. Lubricate the union threads using engine oil. Tighten pipings and unions to the prescribed torque wrench. Reconnect the oil delivery and return pipings with the oil radiator lubricating previously the relative threads by using engine oil.
Page 396 Cooling system and lubrication system Refasten the junction springs (1) between compensa- tor and manifolds of cylinders 1-2-3-4. For Brutale 910 S – 910 R (2007) models only: Reassemble the exhaust manifolds by fitting into the right side of the vehicle as illustrated in the figure. Screw the fixing nut of the flange (1) without tightening.
Page 397 Cooling system and lubrication system Tighten the pin from the left side of the housing. Tighten the compensatory housing fixing pin. Reconnect the lambda probe connector. Tighten the fixing nut of the flange (1) to the prescribed torque. Torque wrench setting for exhaust flange nut: 20 ÷...
Page 398 Cooling system and lubrication system Reassemble the oil radiator protection securing it by the appropriate screws. Before replacing the cap, make sure it is thoroughly clean and replace the sealing ring with a new one. On the oil drain plug there is a magnet for attracting any ferrous residuals which could form in the engine during the rotation.
Page 399 Cooling system and lubrication system Refill to the correct level. Close the oil filler cap. BRUTALE 910 S - R Only for the Brutale 910 S - 910 R model: Before replacing the filler cap, grease the O-ring (1) with the silicon grease (see figure). Tighten the cap (2) to the tightening torque indicated.
Page 401: Special Tools
Special tools SECTION Revision 3 - 1 -...
Page 402 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 403 Special tools Code Q.ty Note B4 750 ORO B4 750 S B4 910 S B4 910 R Descrizione Description I FRAME I I ENGINE I 800092872 • • • • Chiave perno Front wheel ruota anteriore spindle spanner 800091645 • •...
Page 404 Special tools - 4 -...
Page 405 Special tools Code Q.ty Note B4 750 ORO B4 750 S B4 910 S B4 910 R Descrizione Description I FRAME I I ENGINE I 800092867 • • • • Attrezzo montaggio Equaliser pacco bilanciere pack tool 800092868 • • •...
Page 406 Special tools - 6 -...
Page 407 Special tools Code Q.ty Note B4 750 ORO B4 750 S B4 910 S B4 910 R Descrizione Description I FRAME I I ENGINE I 800094792 • • • • Attrezzo montaggio Gear change cambio mounting tool 800086119 • • •...
Page 408 Special tools - 8 -...
Page 409 Special tools Code Q.ty Note B4 750 ORO B4 750 S B4 910 S B4 910 R Descrizione Description I FRAME I I ENGINE I 8000A1874 • • • • Attrezzatura per Fuel tank sostegno serbatoio support benzina assembly 8000A0965 •...
Page 410 Special tools - 10 -...
Page 411: Torque Pressures
Torque pressures SECTION Revision 3 - 1 -...
Page 412 Torque pressures SUMMARY TORQUE PRESSURES – CYCLE PARTS, EXCLUDING ENGINE - BRUTALE 750 S FRAME ..............PAGES 4-5 HANDLEBARS AND CONTROLS .
Page 413 Torque pressures SUMMARY TORQUE PRESSURES – CYCLE PARTS, EXCLUDING ENGINE - BRUTALE 910 S (MY 2007) FRAME ..............PAGES 10-11 HANDLEBARS AND CONTROLS .
Page 414 Torque pressures - 4 -...
Page 415 Torque pressures - 5 -...
Page 416 Torque pressures - 6 -...
Page 417 Torque pressures - 7 -...
Page 418 Torque pressures - 8 -...
Page 419 Torque pressures - 9 -...
Page 420 Torque pressures - 10 -...
Page 421 Torque pressures - 11 -...
Page 422 Torque pressures - 12 -...
Page 423 Torque pressures - 13 -...
Page 424 Torque pressures - 14 -...
Page 425: Diagnostics
Diagnostics SECTION Revision 1 - 1 -...
Page 426: Electrical Parts
Diagnostics DIAGNOSTICS ELECTRICAL PARTS CHARGING SYSTEM Battery warning light on Defective alternator Substitute Defective alternator connection Check Defective battery Substitute Recharging fuse (40A) burnt out Substitute Defective recharging fuse connection Deoxidise/replace Oxidised battery connections Deoxidise/replace SERVICES ELECTRICAL SYSTEM 12V No function is operative Defective ignition switch Substitute Defective ignition switch connection...
Page 427 Diagnostics Horn does not function D4 fuse burnt out Substitute Defective D4 fuse connection Deoxidise/replace Defective klaxon Substitute Direction indicators do not function D4 fuse burnt out Substitute Defective D4 fuse connection Deoxidise/replace Defective intermittency Substitute Defective intermittency connection Deoxidise/replace Bulbs burnt out Substitute Defective bulb connection...
Page 428 Diagnostics INJECTION IGNITION IAW 1.6M Pressure sensor/air temperature signal error Defective sensor Substitute Defective sensor connection Deoxidise/replace Butterfly valve potentiometer signal error Defective potentiometer Substitute Defective potentiometer connection Deoxidise/replace Engine temperature sensor signal error Defective engine temperature sensor Substitute Defective engine temperature sensor connection Deoxidise/replace FUEL INJECTION SYSTEM Injector does not inject fuel...
Page 429 Diagnostics FRONT WHEEL Front wheel oscillates/vibrates Bent wheel rim Substitute Wheel not balanced Balance the wheel Defective tyre Substitute Non-recommended tyre Substitute Damaged wheel bearings Substitute Wheel fixing screws not tightened Tighten Wheel spindle fixing ring not tightened Tighten Front wheel does not turn easily Damaged bearings Substitute Bent wheel spindle...
Page 430 Diagnostics Insufficient braking power Discs dirty Clean Air bubbles in the braking system Bleed Leakages in the braking system Repair Damaged pincer seals Substitute Damaged pump seals Substitute Pincer pistons do not operate smoothly Check Low brake fluid level Top-up Deformed brake discs Substitute Brake pads brush against the discs...
Page 431: Analytical Index
Analytical index SECTION Revision 3 - 1 -...
Page 432 MANUAL Magnesium components (F4 BRUTALE 750 ORO) ....B-7 Chapter A - General Description Maintenance and tuning operations ..B-10 Glossary and symbols .
Page 433 Analytical index Motor control -position of the parts Rpm indicator ......E-45 (BRUTALE 750 ORO - S/910S - R MY 05/06) .D-6 Semiconductor parts .
Page 434 Analytical index Frame control reference measurements ..G-18 Disassembling electric fan Frame disassembly .....G-14 (BRUTALE 750 ORO - S/910S - R MY 05/06) .L-12 Frame removal preliminary operations .
Page 435 Analytical index Instrumentation ......N-6-7 Nuts and screws not indicated in the table .N-12-13 Nuts and screws not indicated in the table . . .N-6-7 Rear suspension .

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750 s 910 s 910 r

MV Agusta F4 BRUTALE 750 ORO Workshop Manual

Table of Contents

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Bodywork

Air Intake Injection System

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Section

Frame

Brakes

Cooling System and Lubrication System

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Summary of Contents for MV Agusta F4 BRUTALE 750 ORO