MV Agusta F4 1000 Workshop Manual
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MV Agusta F4 1000 Workshop Manual

MV Agusta F4 1000 Workshop Manual

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Summary of Contents for MV Agusta F4 1000

  • Page 2 © 2010 The reproduction, even partial of this document is forbidden without prior written agreement of MV Agusta S.p.A. Part no. 8A00B4301 - Edition no. 1 Printed – May 2010...
  • Page 3 Motorcycle workshop manual MV AGUSTA F4 1000...
  • Page 4 Everything that we do has repercussions on the entire planet and its resources. MV Agusta, wanting to protect the interest of the people, would like to make the client and the technicians of the technical assistance centres aware and to adopt modalities of use of the motorcycle and the disposure of its parts in full respect of the norms in force in terms of environmental pollution, disposal and the recycling of waste.
  • Page 5 Freni General Index GENERAL DESCRIPTION..................Rev. 0 MAINTENANCE ......................Rev. 1 BODYWORK ......................Rev. 0 AIR INTAKE INJECTION SYSTEM ................Rev. 1 ELECTRICAL SYSTEM .................... Rev. 1 SUSPENSION AND WHEELS .................. Rev. 0 FRAME ........................Rev. 1 BRAKES........................Rev. 0 COOLING SYSTEM ....................
  • Page 7 General description SECTION Revision 0 - 1 -...
  • Page 8 General description SUMMARY HOW TO CONSULT THIS MANUAL ........... . .PAGE 3 THE PURPOSE OF THIS MANUAL .
  • Page 9 All information, instructions and technical data included in this manual are based upon information on the prod- uct updated at the moment of going to print. MV Agusta S.p.A. reserves the right to carry out changes at any moment without prior notice and without incurring any obligation.
  • Page 10 General description GLOSSARY AND SYMBOLS This signifies that the lack ATTENTION incomplete Use the recommended suspension fluid. observance of this advice can be gravely dangerous for your safety and for the safety of other persons. This signifies that the lack Use the recommended coolant.
  • Page 11 General description RIGHT HAND AND LEFT HAND STANDARD To clarify the right hand and left hand standard that is used in this manual, herewith below is a diagram of the motorcycle and the engine against which are indicated the right and left sides. Cylinder 2 Cylinder 3 Cylinder 1...
  • Page 12 • 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 • Slackening or tightening nuts or screws, always start with those of a greater dimension or from the centre. Always respect the torque values indicated. • Utilise only MV Agusta spare parts. INDEX GENERAL INDEX SUMMARY OF EACH CHAPTER...
  • Page 15 General description OPERATIVE TECHNICAL SPECIFICATIONS MOTORCYCLE IDENTIFICATION The registration number of the motorcycle is stamped on the right side of the steering head. The engine registration number is stamped on the upper engine casing, near the forks. 2) Engine registration number 1) Frame registration number 3) Homologation date Below is an example of the designation of the frame registration number:...
  • Page 16 General description - 10 -...
  • Page 17 Maintenance SECTION Revision 1 - 1 -...
  • Page 18 Maintenance SUMMARY TECHNICAL INFORMATION ............PAGE 3 PERIODICAL MAINTENANCE SCHEDULE .
  • Page 19 Maintenance TECHNICAL INFORMATION 2100 1430 TECHNICAL DATA Description F4 1000 CHARACTERISTICS Wheelbase (mm) (*) 1430 Total length (mm) (*) 2100 Maximum width (mm) Seat height (mm) (*) Ground clearance (mm) (*) Trail (mm) (*) 100,4 Dry weight (kg) Fuel tank capacity (lt) (**)
  • Page 20 Maintenance TECHNICAL DATA Description F4 1000 TIMING Type D.O.H.C. radial valves LUBRICATION Type Wet sump IGNITION - FUEL FEED SYSTEM Type “Magneti-Marelli” IAW 7BM integrated ignition-injection system with Mikuni throttle body; inductive discharge electronic ignition; “Multipoint” phased sequential electronic injection;...
  • Page 21 Maintenance TECHNICAL DATA Description F4 1000 TYRES Front 120/70-ZR 17 (58 W) Rear 190/55-ZR 17 (75 W) Brand and type PIRELLI - Diablo Supercorsa SP DUNLOP - Sportmax Qualifier RR Tyre pressure (*) At a speed lower than 300 km/h...
  • Page 22 Everything that we do has repercussions on the whole planet and on its resources. MV Agusta, to protect the interests of the everyone, ask clients and technical assistance operators to use the motorcycle and dispose of its used parts with respect to the norms in force in terms of environmental pollution, disposal and recycling of refuse.
  • Page 23 Maintenance Programmed maintenance schedule 1000 6000 12000 18000 24000 30000 36000 Km (mi) covered (600) (3800) (7500) (11200) (14900) (18600) (22400) Pre- Service delivery Description Operation Check / adjust Transmission and flexible controls Check / adjust Drive chain Lubricate Substitution Check Front sprocket / stop washer Substitution...
  • Page 24 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 25 Maintenance Place a container underneath the engine to collect the used oil. Remove the oil discharge plug (1). Recover the oil in an appropriate container. Do not scatter the drainage oil into the envi- ronment. Allow the lubrication system to drain completely. Substitution of the oil filter Remove the 4 fixing screws (2) of the oil filter cover.
  • Page 26 Maintenance Replace the oil filter and put the cover back on. On the oil discharge plug there is a magnet to attract any metal residues that could form in the engine during rotation. Before replacing the cap, make sure it is completely clean.
  • Page 27 Maintenance Switch on the engine for several minutes. After switching off the engine, wait at least ten minutes and then check the oil level. Ensure that the motorcycle is placed on level ground and is in a vertical position. The correct level must be as close as possible to the “MAX”...
  • Page 28 Maintenance If the level is under the minimum line, proceed with top- ping-up as follows: With the engine cold, top up the level using the filler hole (2) of the expansion tank. Open the expansion tank only when the engine is cold; the discharge of boiling liquid could cause burns.
  • Page 29 Manutenzione Maintenance Engine coolant substitution Substitution¡ every two years Before proceeding the emptying of the system, remove: The ignition switch cover (see “Engine coolant level check”); The under-engine fairing; left fairing panel (see chapter “Bodywork”); Place a container under the engine to collect the used coolant;...
  • Page 30 Maintenance Maintenance Check once again the level of the coolant inside the expansion tank, which should be between the «MIN» and «MAX» mark found on the expansion tank. If the level is inferior to the «MIN» mark, top up the coolant level by pouring new coolant into the filler hole.
  • Page 31 Maintenance Maintenance VALVE MECHANISM ADJUSTMENT Check and adjust ¡ at 1000 kilometres and every 12000 kilometres Remove in order the following components to carry out the measuring of the play between the camshaft and the valve cups: • Left side fairing panel •...
  • Page 32 Maintenance Maintenance Remove the locking bracket of the plug-top coils. Remove the 4 plug-top coils as shown in Chapt. G "Frame". To install the locking bracket of the plug-top coils, make sure the bends of the bracket are turned upwards, as shown in the figure.
  • Page 33 Maintenance Lift the front part of the motorcycle as shown in the figure. Remove the plastic covers (1) and remove the 8 fixing screws of the cover of the engine head (2). Remove the wiring clamps on the right side of the frame.
  • Page 34 Maintenance Disconnect the connectors shown in the figure. Remove the wiring from the frame. Operating as shown in the figure, slightly lift up the cylinder head cover. To carry out this operation, use only the work surfaces indicated. Take care to not ruin or deteriorate the motorcycle parts in the proximity of the work area.
  • Page 35 Maintenance Maintenance Proceed with the removal of the engine head cover as shown in the figure. Utilising a syringe, remove the surplus oil that is left in the various niches in proximity to the valve cups. Proceed with the removal of the timing wheel cover by unscrewing the five fixing screws.
  • Page 36 Maintenance Maintenance Rotate the camshaft by turning the central nut in an anti-clockwise direction to bring piston N° 1 of the engine to the Top Dead Centre position (T.D.C.) when the piston is at its uppermost part of the compression stroke.
  • Page 37 Maintenance Maintenance Utilising a feeler gauge of the type shown in the figure, measure the play between the camshaft and the valve cups. The correct measuring of the play is a fun- damental operation for the correct function- ing of the engine. Carry out the measuring of the play of the following valves: Cylinders 1 and 2 intake valves...
  • Page 38 Maintenance Maintenance The progressive numeration of each valve is illustrated EXHAUST in the photograph on the right. Note the anti-clockwise direction of the numeration. INTAKE To facilitate the operation, it is possible to note before- hand and in order the play values revealed on the strip of adhesive tape applied to the openings of the air intake conduits.
  • Page 39 Maintenance Maintenance Check again the timing of the engine, ensuring that the incision stamped on the timing wheel is aligned with the “tooth” on the engine casing. Continue with the measuring of the play of the follow- ing valves: Cylinders 3 and 4 – intake valves (n° 5, 6, 7, 8). Cylinders 2 and 4 –...
  • Page 40 F4 1000 workshop engine manual F4 1000 (Code 8000B4302). If the values are correct, reassemble in reverse order to disassembly. Consult the F4 1000 workshop engine man- ual (Code 8000B4302) for the specific torque pressures and the necessary products.
  • Page 41 Maintenance Maintenance Timing chain, mobile timing chain guide and timing chain tensioner Timing chain and mobile timing chain guide: Check ¡ Every 12000 kilometres Substitute ¡ Every 36000 kilometres Timing chain tensioner: Check / substitute ¡ Every 12000 kilometres To disassemble these parts and not being a part of nor- mal maintenance, it is necessary to proceed as described in the overhaul section of the F4 workshop engine manual (Part.
  • Page 42 Maintenance Maintenance Heat Grade Check the heat grade of the spark plugs. Sparks: - NGK CR9 EB DO NOT use non-resistive spark plugs. Spark plug gap If appropriate (see Technical Data table), measure the spark gap with a thickness metre. Adjust the gap if necessary on the basis of the following information: Sparks Spark plug gap...
  • Page 43 Maintenance Maintenance FUEL FILTERS Check and substitute ¡ Every 12.000 km For the checking or substitution of the engine intake system filters (fuel filter, fuel pump filter), it is neces- sary to remove in sequence the following parts: • Fuel tank side panels •...
  • Page 44 Maintenance Completely empty the fuel tank utilising a pump as illustrated in the figure. Petrol flange assembly removal Turn the tank upside down and remove the eight screws for fixing the flange to the tank (1). Lift up the flange (1) and disconnect the tubes (2) on both sides of the flange.
  • Page 45 Maintenance Extract the complete flange assembly (1). Disconnect the electric connectors of the fuel pump (1). Checking and replacing the O-Ring Check the condition of the O-Rings (1) which seal the flange (2). Make sure that the components are perfectly intact and lubricate with silicone grease.
  • Page 46 Maintenance Maintenance During re-assembly, if the O-Rings have been repla- ced, lubricate surface lightly with silicone grease. The use of worn O-Rings can lead to a leaka- ge of petrol from the tank with a consequent risk of fire for the vehicle. Replacing the thermistor If the thermistor needs to be replaced, the cable clamp must be cut.
  • Page 47 Maintenance Maintenance Take the thermistor out of its housing and replace with a new one. Reconnect the connector and fix a new clamp (Cod. 800056783). Replacing the filter cartridge If the filter cartridge needs to be replaced, it is first necessary to remove the lower clamp and take the tube out of the cartridge.
  • Page 48 Maintenance Maintenance Remove the filter cartridge and replace with a new one. Insert the upper tube in the new cartridge and fix with a clamp taken from the new kit, using the special tool. Pneumatic pincer: Oetiker HO 3000 ME Insert the lower tube in the new cartridge and fix with a clamp taken from the new kit, using the special tool.
  • Page 49 Maintenance Maintenance FUEL PUMP ASSEMBLY - 33 -...
  • Page 50 Maintenance Maintenance Fuel flange unit assembly Before starting the assembly of the flange to the fuel tank, check the condition of the two small overflow tubes connected to the lower part of the fuel filler cap. If these components are not in perfect condition, sub- stitute them and position the band fasteners as shown in the figure.
  • Page 51 Maintenance Maintenance Position the flange unit (1) inside the fuel tank. Check that the two small overflow tubes (2) remain out- side of the fuel tank. Insert two CLIC R 96 105 band fasteners (1) onto the small tubes. Insert the two small rubber tubes (2) onto the appropriate spigot on the die-cast flange.
  • Page 52 Maintenance Maintenance TUBES / FUEL FITTINGS Check for leaks ¨ First 1000 kilometres and then every 6000 kilometres Carry out a visual check for eventual leakages from the fuel feed tubing and the unions (see figure). Substitute damaged parts if leaks or evaporation are found.
  • Page 53 Maintenance Maintenance ADJUSTMENT AND CALIBRATION OF THROTTLE BODY After connecting to the control unit diagnostic software and before starting the engine, immediately check the throttle position: 2.3 degrees (min 1.9, max 2.6) If the position should not enter within the recommended field, reset with the TPS function, WITHOUT TOUCHING THE MECHANICAL ADJUSTMENT SCREWS OF THE THROTTLE.
  • Page 54 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 55 Maintenance The number of engine revs at idling should be kept at the following values: IDEAL 1150 rpm (min 1100 - max 1200) The system is able to balance engine running around the target speed 1150 rpm - 50 rpm acting automati- cally on the ignition advance.
  • Page 56 Maintenance Air Filter Check/substitute ¨ Every 6000 kilometres Certain parts must be removed in sequence before acceding to the air filter. See chapter C “Bodywork”. • Seats • Right side panel tank • Left side panel tank • Rear right side panel •...
  • Page 57 Maintenance Unhook the two front clips (3) and remove the cover (4). Remove the filter (5). Check the condition of the air filter. If it is necessary to substitute it, proceed as follows: Prepare a new air filter. Check that the inside of the air filter compartment is clean and free from foreign bodies.
  • Page 58 Maintenance Maintenance Take the upper Airbox cover and remove the gasket with the aid of a screwdriver. Position the gasket on the edge of the lower Airbox. Position the upper Airbox cover. - 42 -...
  • Page 59 Maintenance Maintenance Fasten the cover with four screws (two per side) (6). Proceed with the assembly of the parts listed below and according to the procedure described in chapter C “Bodywork”. • Fuel tank • Left side panel Airbox • Right side panel Airbox •...
  • Page 60 Maintenance Maintenance BRAKES AND CLUTCH Check the levels of fluid in the systems¨ At pre-delivery, at first 1000 kilometres and then every 6000 kilometres. Check for leakages¨ At pre-delivery, at first 1000 kilometres and then every 6000 kilometres. Substitute fluid¨ Every 24000 kilometres or at least every two years Commands check¨...
  • Page 61 Maintenance Maintenance Before completing the operation, clean and wash accu- rately with alcohol the three components of the fluid chamber cover and blow to dry them. Clean the edge of the fluid chamber with a clean cloth. Close the fluid chamber with the two relative screws. Imperfect cleaning of these parts could cause the discharge of small quantities of brake fluid during riding.
  • Page 62 Maintenance Maintenance Checking the level of the rear brake fluid No parts of the vehicle need to be removed from the vehicle to check the level of the rear brake fluid. If the fluid is below the low level mark, follow these steps to top up with brake fluid complying with the spec- ifications: remove the saddle and the fuel tank;...
  • Page 63 Maintenance 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 64 Maintenance 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 65 Maintenance Maintenance BRAKE PADS Wear check / substitute ¨ At the first 1000 kilo- metres and then every 6000 kilometres Check the condition and thickness of the brake pads on the calipers. Front brake caliper Rear brake caliper Measure the thickness of the pad linings. If the thick- ness of the linings is equal to or less than the wear limit shown below, replace the pads as described in chapter H “Brakes”.
  • Page 66 Maintenance Maintenance After making adjustments, check that the throttle valves open slightly by activating the choke lever (1) as indicated in the following figure. If interventions have been carried out on the throttle bodies, the transmission of the throttle control must be analysed not only at the throttle control handgrip but also near to the throttle bodies.
  • Page 67 Maintenance Maintenance LOCKS Check ¨ At the pre-delivery, at the first 1000 kilometres and then every 6000 kilo- metres. Ignition/steering block switch This switch has four operating positions. Do not attach key rings or other objects to the ignition key that could obstruct the rota- tion of the steering.
  • Page 68 Maintenance Maintenance Fuel cap lock Lift up the anti-dust cover. Insert the key, rotating it in a clockwise direction and lift up the cap. After refuelling, press the cap down and rotating the key contemporaneously to facilitate the closure. Let the key go free, bring it into a longitudinal position and pull it out.
  • Page 69 Maintenance Maintenance STEERING Check and adjust ¨ At the first 1000 kilometres and then every 12000 kilo- metres. Check the steering components regularly according to the above-mentioned intervals. If it is necessary to carry out adjustments, operate as described in chapter F “Suspension and wheels”. TRANSMISSION CHAIN Check ¨...
  • Page 70 Maintenance Maintenance Regulation¨ At the first 1000 kilometres and then every 6000 kilometres. To adjust the chain tension, proceed as follows: Slightly slacken the two screws of the rear wheel hub. Loosen the 2 rear wheel hub screws. Using the special spanner as indicated in the figure, move the eccentric adjuster nut backwards or forwards respectively slackening or tightening the chain, until the correct play is reached (as described previously).
  • Page 71 Maintenance Maintenance Chain lubrication Lubricate¨ At the first 1000 kilometres and at 6000 kilometres and then at every 12000 kilometres. The chain is of the O-ring type. Clean the chain with a clean cloth and/or a jet of air. Apply the lubricant after cleaning. Utilise only the recommended lubricants or the equivalent (see page B-8).
  • Page 72 Maintenance 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 73 Maintenance Maintenance WHEELS Visual check ¨ At the first 1000 kilometres and then every 6000 kilometres (at least every tyre change) After having visually checked or following even light collision damage, it is necessary to check the planari- ty, the eccentricity and the ovalisation of the wheel. See the control procedures described in chapter F “Suspension and wheels”.
  • Page 74 Carry out a check on the length of the rear shock absorber spring; check for leakages and trickles of oil and also check the adjustment function. Spring adjustment standard A: - F4 1000: A = 170,5 mm The shock absorber contains gas under high pressure. Do not touch the shock absorber valve.
  • Page 75 Maintenance Maintenance SIDE STAND Functional check ¨ At the pre-delivery, first 1000 kilometres and then every 6000 kilometres Make sure the bike cannot be started when the stand is down and the bike is in gear. Also check that with the engine switched on, when the side stand is lowered and a gear is engaged, the engine switches off auto- matically.
  • Page 76 It is therefore necessary to substitute the fork oil at the prescribed intervals. Quantity oil: 720 cc (*) - F4 1000: (*): approximate quantity calculated in relation to the actual maintenance level Oil type used: SAE 7,5...
  • Page 77 If the warning light comes on even if the oil level is correct, do not resume riding and con- tact a MV Agusta authorized service centre. 6 Sidestand down warning light (red) Lights up when the sidestand is down.
  • Page 78 Maintenance Maintenance Multifunction display 10 Thermometer It displays the temperature of the coolant by turning on a variable number of segments on a graduated scale. When the temperature falls outside the nor- mal operating range, it may display one of the fol- lowing information: - the display shows just one blinking segment;...
  • Page 79 Maintenance Maintenance Selecting and setting the display functions Some of the main measurements of the instruments may be changed. The available options include: - Select an operating mode: “RUN” (Odometer) “TC” (Traction control) “CHRONO” (Chronometer) “NIGHT/DAY” (Night/Day Mode) - Reset the trip counter: Trip counter 1 “TRIP 1”...
  • Page 80 Maintenance Maintenance “RUN” mode In addition to the speedometer, the display shows the following functions: • Total odometer “TOTAL” • Trip counter 1 “TRIP 1” alternatively: • Total odometer “TOTAL” • Trip counter 2 “TRIP 2” “TC” Mode This Mode adjusts the engine traction control level to your driving requirements.
  • Page 81 Maintenance Maintenance “NIGHT/DAY” Mode This function enables the background colour of the dis- play to be converted in order to adapt its visibility depending on the time of day or night the vehicle is used. Trip reset To reset “TRIP 1” and “TRIP 2”, proceed as follows. WARNING The display modes may be changed or set when the engine off, the gear in neutral, the...
  • Page 82 Maintenance - Press the “OK” key for less than four seconds until the partial speedometer 2 function (“TRIP 2”) appears on the display. - By pressing the “OK” key for more than four seconds, the “TRIP 2” value will be reset to zero. “TC”...
  • Page 83 Maintenance - Press “SET” for less than four seconds: the traction control level rises up to the next value. Such value may range between 0 and 8. - Press “OK” for over four seconds to confirm the selec- ted traction control level. Chronometer Lap timing acquisition - Turn on the chronometer (“CHRONO”...
  • Page 84 Maintenance - Press the headlight button again to record the time taken to cover the 1st lap. At the same time, the instrument starts recording the time taken to cover the second lap. The time measurement for the first lap is stored in the memory and is visualised on the display for ten sec- onds, after which the time measurement for the follow- ing lap appears.
  • Page 85 Maintenance - Press “OK” for less than four seconds until “LAPS VIEW” appears. - By repeatedly pressing the key of the flashing high beam headlight, all the times previously acquired starting from the last lap memorised can be displayed in sequence. - Once all the data have been displayed, press the “SET”...
  • Page 86 Maintenance How to delete data To delete the saved data, proceed as follows: WARNING The display modes may be changed or set when the engine off, the gear in neutral, the motorbike stationary with your feet on the ground. Do not change the display while dri- ving.
  • Page 87 Maintenance - Subsequently, by pressing the flashing high beam headlight key followed by the “OK” key for more than four seconds, all the previously acquired times can be cancelled. - Once all the data have been cancelled, press the “SET” key to return to the “SINGLE LAP RESET” mode and then to the following mode.
  • Page 88 Maintenance - Now, press “OK” for over four seconds to delete the value. Otherwise, press “SET” for less than four seconds to stop the deletion procedure. - Once all the data have been cancelled, press the “SET” key to exit the “BEST LAP RESET” mode and then pass to the following mode.
  • Page 89 Maintenance - By pressing the “OK” key for more than four seconds, all the previously acquired times will be cancelled. By pressing the “SET” key for less than four seconds, the cancellation procedure will be interrupted. - Once all the data have been cancelled, press the “SET”...
  • Page 90 Maintenance “IMMOBILIZER” function The "IMMOBILIZER" function allows the engine to be started up only after an original ignition key is recogni- sed. It is in fact an anti-theft system integrated into the electronic circuit of the vehicle, since it prevents use by any unauthorised individuals.
  • Page 91 “IMMOBILIZER”. Repeat the code entry procedure from the start, taking care of setting all the right digits shown on your MV Code Card. If the problem persists, contact a MV Agusta licensed service centre. - 75 -...
  • Page 92 How to select the mapping of the control unit It is possible to select special mapping on the control unit of the F4 1000 model which allows you to obtain higher power and performance characteristics for deci- dedly sporty use of the vehicle.
  • Page 93 Whenever a fault is detected while the vehi- cle is running, stop running and contact an authorised MV Agusta service centre. - When the vehicle is stopped, the display will show an error message detailing the motorcycle unit or com- ponent where the malfunction was detected.
  • Page 94 If it is necessary to top up coo- ling liquid, contact an authorised MV Agusta service centre. If the indicator lights up even though the level is correct, do not con- tinue to run and contact an authorised ser- vice centre.
  • Page 95 Maintenance “SERVICE” Mode This operating mode displays the mileage range with respect to expiration of the next scheduled maintenan- NOTE When the mileage range upon maintenance servicing is less than 1000 km, its relative value automatically appears after the start-up screen of the motorcycle. “UNIT CHANGE”...
  • Page 96 Maintenance - Press the "OK " button for less than four seconds until the message "SERVICE" is displayed. The mileage range with respect to expiration of the next scheduled maintenance is shown on this screen. - Mileage range resetting: After performing scheduled maintenance, the mileage range must be reset using the following procedure.
  • Page 97 Maintenance Changing the unit of measurement Allows for simultaneous editing of the following units of measure: • Speed • Distance covered WARNING The modification or adjustment of display functions must be carried out with the engi- ne off and running on neutral, with the motorcycle stopped with the stands on the ground.
  • Page 98 Maintenance - Press the "OK " button for more than four seconds and the new unit of measurement configuration will be confirmed. The display returns to the "RUN" mode. LIGHTS Check ¨ At the pre-delivery, at the first 1000 kilometres and then every 6000 kilo- metres.
  • Page 99 Maintenance Turn the holding device counter-clockwise. Remove the bulb. Disconnect the connector. - 83 -...
  • Page 100 Maintenance Maintenance Connect the connector on the new bulb. Insert the new bulb, blocking it in position as shown in the figure. Caution: Do not touch the bulb glass with your hands. In case of contact, clean with a degreasing product. Turn the holding device clockwise.
  • Page 101 Maintenance Maintenance Replacing the license plate light bulb - Remove the fixing screws of the lower cover of the license plate holder. - Remove the lower cover. - 85 -...
  • Page 102 Maintenance - Extract the bulb socket sliding it from its seat. - Extract the bulb. - Insert the new bulb. - Reposition the bulb socket. - Reassemble the lower cover of the license plate holder. Caution: Before reassembling pay special attention to positioning the tail light harness correctly, in order to avoid any damage (see figure).
  • Page 103 Maintenance Replacing the fuses - The battery recharge fuse is located on the solenoid starter of the motorcycle. To expose it, remove the rider’s saddle. Solenoid starter CAUTION Turn the ignition key on the “OFF” position before checking or replacing the fuses, in Recharge fuse (40 A) order to avoid a short circuit with subse- Spare fuse (40 A)
  • Page 104 Maintenance Maintenance - The service fuses are located on the left side. To expose them, remove the side fairing - Release the two clamps and lift the fuse box cover. CAUTION Turn the ignition key on the “OFF” position before checking or replacing the fuses, in order to avoid a short circuit with subse- quent damage to other electric parts of the motorcycle.
  • Page 105 Maintenance Maintenance To identify the position and function of the fuses, refer to the information shown in the enclosed electrical diagram. The reference letters in the figure corre- spond to those shown in the diagram. Remember that the tool bag contains three spare fuses.
  • Page 106 Maintenance Maintenance FRONT HEADLAMP Check adjustment ¨ At every variation of the motorcycle set-up. The headlight should be adjusted every time the geometry of the vehicle is altered and before carrying a pillion passenger. The motorcycle is not equipped with external adjusters and the front projector unit is fixed to the frame. Headlight adjustment Place the vehicle at a distance of 10 m from a vertical wall.
  • Page 107 Bodywork SECTION Revision 0 - 1 -...
  • Page 108 Bodywork SUMMARY FAIRING ASSEMBLY ............. . .PAGE 3 TAIL UNIT .
  • Page 109 Bodywork FAIRING ASSEMBLY Right side Left side • This exploded view demonstrates the position of the bodywork and the method of disassembly and assembly. - 3 -...
  • Page 110 Bodywork Fairing side panel removal Remove the seven fixing bolts (1) situated on the right fairing side panel. Remove the fairing side panel, sliding it off from the front side. Repeat the operation for the left fairing side panel. To separate the air manifold from the side panels, removing the two fixing screws (2).
  • Page 111 Bodywork Under-engine fairing removal Remove the three fasteners (1) placed respectively: 1 on the right side; 1 on the left side; 1 on the front central part; Remove the underfairing, sliding it off from the bracket (2). - 5 -...
  • Page 112 Bodywork Front fairing removal With a small flat-tip screwdriver, remove the connector (1) of the front headlight. Push the screwdriver forward to unhook the connector. Remove the two fixing screws (2) of the right rear-view mirror. Remove the connector and take off the right rear-view mirror (3).
  • Page 113 Bodywork Remove the two fixing screws (1) of the headlight fair- ing to the instrument panel support. Remove the two fixing screws (2) of the headlight fair- ing support on both sides. Remove the headlight fairing, sliding it toward the front part.
  • Page 114 Bodywork TAIL UNIT - 8 -...
  • Page 115 Bodywork Tail unit removal Insert the ignition key into the seat lock. Press lightly on the rear part of the passenger seat as shown in the figure. Turn the key and unlock the TAIL UNIT. Lift up the passenger seat. Press the driver seat release lever (1) and remove, sliding it from the rear part.
  • Page 116 Bodywork Remove the tank side fairings (1) on both sides, unhooking it from the pin and sliding it toward the rear part of the motorcycle (page C.12). Remove the right under seat side fairing removing the 5 screws (2). - 10 -...
  • Page 117 Bodywork Remove the side fairing toward the outside, taking care of the rear pin anchored in the support brackets. - 11 -...
  • Page 118 Bodywork FUEL TANK - 12 -...
  • Page 119 Bodywork Side fairing removal Extract the left and right side fairing support as indicat- ed in the figure. Extract the rear part of the support first (A) then grad- ually withdraw the support from its front seat fixing (B). Remove the vent tube. Fuel tank removal Remove the rear fixing screw of the fuel tank (1).
  • Page 120 Bodywork Remove the two fixing screws (1) of the tank support bracket. Lifting the rear part of the tank, remove the bracket. Lift up the fuel tank. While lifting the tank take care not to dam- age the airbox. - 14 -...
  • Page 121 Bodywork Then position the special tank support tool in corre- spondence with the hole (1) on the seat seal and with the two tank support bracket fixing holes (2) on the rear frame. Special tool Code 8000B4414 Insert the tank on the tool support spindle as shown in the figure and disassemble electrical connections.
  • Page 122 Bodywork To disconnect the fuel tube, press and slide the retaining slide as shown in the figure. Disconnect the electrical system connector. Disassemble the duct cover panels Remove the two connecting screws (1) of the right panel (2) of the frame. - 16 -...
  • Page 123 Bodywork Lift the panel and unhook it from the two pins. Remove it outward. Repeat operations for the left panel. Disconnect the air temperature sensor connector. Remove the sensor electrical cable from the guides on the right duct. - 17 -...
  • Page 124 Bodywork From the left duct, remove the left direction indicator light electrical cable from the guides. Left and right air intake conduit removal Unhook the connector pin (1) on the ducts. Remove the right air intake conduit. Proceed with disassembly of the right air duct (2), turn- ing the front part outward.
  • Page 125 Bodywork Remove the right and left suction duct unions (1) before removing the airbox. Air filter compartment side panels Remove the left and right air filter compartment side panels by unscrewing the two relative screws (1). Before reassembly, check the integrity of the elastic nuts and replace if necessary.
  • Page 126 Bodywork AIR INTAKE SYSTEM - 20 -...
  • Page 127 Bodywork Airbox removal Remove the 4 fixing screws (2 per side) of the airbox cover. Remove the air box cover. Remove the cover by lifting it up. - 21 -...
  • Page 128 Bodywork Remove the two fixing screws (1) of the control unit support plate and remove the plate. Unhook the clamp with the clip grippers on the valve of the TSS and disconnect the tube. Unhook the gas tube pressing the coloured button (1) to unhook it from the union (2).
  • Page 129 Bodywork Unhook the oil vapour tube. Lift the air box from its rear part, removing the rubber tube. Disconnect the upper injector cable connector. - 23 -...
  • Page 130 Bodywork Remove the cable. With the appropriate gripper, loosen the secondary valve tube clip and remove the tube. Lift and remove the airbox. - 24 -...
  • Page 131 Bodywork HEAT SHIELD - 25 -...
  • Page 132 Bodywork Heat shield removal After having removed the seats and the rear fairings as previously described, proceed as follows: Remove the silencers (see chapter F “Suspension and wheels”). Remove the battery (see chapt. E - electrical system). Remove the rear headlight connector fastening clip and disconnect the connector.
  • Page 133 Bodywork Remove the headlight support. Remove the 6 fixing screws of the heat guard. Lower and remove the guard toward the rear part. - 27 -...
  • Page 134 Bodywork MUDGUARD - CENTRAL SPOILER - RADIATOR PROTECTION Right side Left side - 28 -...
  • Page 135 Bodywork Central manifold disassembly Remove the flashing relay (1) toward the rear part. Remove the two fixing screws (2) and remove the cen- tral manifold (3). Front mudguard disassembly Unscrew and remove the 4 fixing screws (1) on the mudguard (2 per side). - 29 -...
  • Page 136 Bodywork Remove the number plate holder toward the front part. Oil radiator protection disassembly Unscrew and remove the two screws (1), one per part. To remove the radiator protection, slide it downward removing the reference pin. - 30 -...
  • Page 137 Air intake injection system SECTION Revision 1 - 1 -...
  • Page 138 Air intake injection system SUMMARY INJECTION SYSTEM TECHNICAL CHARACTERISTICS ........PAGE 3 INJECTION TIME COMPENSATION (VOLUME) .
  • Page 139 Air intake injection system INJECTION SYSTEM TECHNICAL CHARACTERISTICS INJECTION TIME (INJECTION VOLUME) The factors for the determination of the injection time are the basic injection time that is calculated on the basis of the r.p.m. of the engine, the opening of the accelerator and various compensations that are determined accord- ing to signals coming from various sensors that reveal the condition of the engine and the riding conditions.
  • Page 140 Air intake injection system INJECTION TIME COMPENSATION (VOLUME) The various sensors allow the injection time (volume) compensations to be carried out on the basis of the fol- lowing signals. SIGNAL DESCRIPTION When the atmospheric pressure is low, the sensor ATMOSPHERIC PRESSURE SENSOR SIGNAL sends a signal to the ECU to reduce the injection time (volume).
  • Page 141 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) and the regulator of the pressure. The fuel in the tank is pumped into the feed tubing at a controlled pressure by the rel- ative regulator and maintained at a certain constant value higher than the suction generated by the motor.
  • Page 142 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/cm (300 kPa).
  • Page 143 Air intake injection system FUEL PUMP CONTROL SYSTEM When the ignition switch is turned to the ON position, the fuel pump motor is started by the current supplied by the battery. As the CPU possesses a timer function, the pump motor stops turning three seconds after the ignition switch has been brought to the "ON"...
  • Page 144 Air intake injection system The ECU is situated under the tank behind the cylinder blocks. The ECU consists of a CPU (Central Processing Unit), a memory unit and I/O sections (input/output). The signal of each individual sensor is sent to the input section and then to the CPU.
  • Page 145 Air intake injection system 2 INTAKE AIR TEMPERATURE SENSOR The temperature of the intake air is found by con- verting the resistance of the Thermistor into voltage and then sending it to the ECU. The volume of the injection increases when the air temperature is low. The resistance of the Thermistor increases when the air temperature is low and diminishes when the tem- perature is high.
  • Page 146 Air intake injection system THROTTLE BODY POSITION The sensor of the throttle position (1) is located in the centre of the throttle body. This sensor is a potentiometer with a resistance which varies according to the opening angle of the accelera- tor.
  • Page 147 Air intake injection system INJECTOR CHECK To check the injectors proceed as follows: - Disconnect a connector from one of the injectors. - Check between green-red and earth. For approxi- mately two seconds the voltage at the ends of the leads should be that of the battery.
  • Page 148 Air intake injection system - Check the functioning of the fuel pump, connecting respectively: Pin 1 of the connector to the + pole of the battery. Pin 2 of the connector to the – pole of the battery. - If the fuel pump unit does not continue to function correctly after the above-described tests, proceed with relative relay control (1) on the left side of the motorcycle, identified by a ring marked with "I"...
  • Page 149 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 150 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 151 Air intake injection system AIR INTAKE SYSTEM TECHNICAL CHARACTERISTICS This motorcycle utilises direct induction in the air intake system. The frontal pressure of the air during normal rid- ing conditions is conducted to the air filter compartment in such a way that the incoming air is pressurised there- by improving the air intake efficiency to obtain greater power from the engine.
  • Page 152 Air intake injection system SECONDARY AIR SYSTEM TECHNICAL CHARACTERISTICS F4 bikes use an additional system for the secondary flow of induction air. Through this system, part of the air from the Airbox is channelled near the exhaust pipes of the cylinder through a set of on/off valves and passageways inside the engine head.
  • Page 153 Air intake injection system POSITIONS OF ENGINE-CONTROL SYSTEM PARTS - 17 -...
  • Page 154 Air intake injection system INJECTION SYSTEM ELECTRICAL DIAGRAM FULE PUMP, INJECTOR FUSE COIL, ECU FUSE FUEL PUMP - COILS - INJECTORS RELAY MAIN RELAY SERVICE FUSE - 18 -...
  • Page 155 Air intake injection system Engine control unit pinout, MV Agusta F4 Connector Vehicle Engine Pin name Description of associated function Type Pin n° Pin n° IGN4 Output coil control N°4 OFA,LOW-SIDE IGN3 Output coil control N°3 OFA,LOW-SIDE SNSSPLY2_GND Analogic mass 2...
  • Page 156 Air intake injection system - 20 -...
  • Page 157 Electrical system SECTION Revision 1 - 1 -...
  • Page 158 ELECTRICAL DIAGRAM F4 1000 ........
  • Page 159 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 • Block couplings – ensure that the block is released CLICK before disconnecting it to push it completely home when connecting it.
  • Page 160 Electrical system SEMICONDUCTOR PARTS • Do not drop semiconductor parts such as those INCORRECT incorporated in the ECU. • When checking these parts, carry out the instruc- tions to the letter. The lack of using the correct pro- cedure can cause grave damage. - 4 -...
  • Page 161 Electrical system ELECTRICAL DIAGRAM F4 1000 - 5 -...
  • Page 162 Electrical system Parts list Parts list Ref. Description Ref. Description Rear stop switch Number plate light Ignition switch Right indicator Safety and Front stop switch Right indicator Left indicator Front headlight Diagnostic connector (5A-serial line Instrument panel RX; 5B-Ground; 5C-serial line TX) Air pressure sensor Main relay Left indicator...
  • Page 163 Electrical system BATTERY The battery mounted on this motorcycle is a sealed battery therefore no maintenance is required. The following battery is used: KOYO KTZ-10S This is a sealed battery with breather valve. No elec- trolyte level checking is required. Never remove the battery seal caps nor block the breather opening.
  • Page 164 Electrical system BATTERY ASSEMBLY 1) Perform the initial charge of the battery according to the instruction to page 7. 2) Insert the motorcycle key in the rear lock. Rotate the key clockwise while removing the pillion. Then remove the rider’s saddle as shown in the picture. 3) Remove the frame plate (1) to facilitate the following operations.
  • Page 165 Electrical system 5) Insert the battery in its proper compartment. 6) Fit the 2 positive terminals (+) on the corresponding battery pole, respecting their disposition as shown in the figure. Rotate the positive terminals screw and tigh- ten it at a torque equal to 7 ÷ 8 Nm. Afterwards, fit the protective cap on the positive pole.
  • Page 166 Electrical system Wait at least twenty-four hours before positioning the battery in the compartment. This is strictly necessary for this motorcycle as the battery is positioned horizontally, as shown in the diagrams below NEGATIVE POLE (-) POSITIVE POLE (+) NEGATIVE CABLE (-) POSITIVE CABLE (+) NEGATIVE CABLE (-) PROTECTIVE CAP...
  • Page 167 Electrical system CHARGING SYSTEM Warning function Conditions of abnormal operation of the battery char- ≥ ging function (voltage 10V) is indicated by the war- ning lamp on the dashboard. As shown in the figure, the temperature influences the characteristics of the regulator with steps of variation of the regulated voltage.
  • Page 168 Electrical system A list of possible problems that could occur when the warning light is switched on. RESTORE OR CLEAN CON- WARNING LIGHT STILL ON SI RISCONTRANO PROBLEMI PROBLEMS OCCUR RIPRISTINARE O PULIRE LA SPIA ANCORA ACCESA NECTION SULLA CONNESSIONE WITH CONNECTION CONNESSIONE POSITIVO SU BATTERIA...
  • Page 169 Electrical system BATTERY EFFICIENCY CHECK Battery current loss check • Remove the seats as described in chapter C “Bodywork”. • Turn the ignition switch to the “OFF” position. • Disconnect the cable from the negative (-) pole of the battery. •...
  • Page 170 Electrical system Measure the DC voltage between the positive (+) and the negative (-) terminals of the battery with a multi- tester. If the tester indicates less than 12.6V or more than 14.5V the cause will be found in the generator. Battery When carrying out this check, ensure that NOTE...
  • Page 171 Electrical system FULE PUMP, INJECTOR FUSE COIL, ECU FUSE FUEL PUMP - COILS - INJECTORS RELAY MAIN RELAY SERVICE FUSE - 15 -...
  • Page 172 Electrical system FULE PUMP, INJECTOR FUSE COIL, ECU FUSE FUEL PUMP - COILS - INJECTORS RELAY MAIN RELAY SERVICE FUSE - 16 -...
  • Page 173 Electrical system FULE PUMP, INJECTOR FUSE COIL, ECU FUSE FUEL PUMP - COILS - INJECTORS RELAY MAIN RELAY SERVICE FUSE - 17 -...
  • Page 174 Electrical system STARTER MOTOR REMOVAL • Remove the fuel tank (see chapter C “Bodywork”). • Drain off the engine coolant, completely emptying the cylinder passageways via the two screws situat- ed on the front part of the cylinders. • Remove the coils from the frame support. •...
  • Page 175 Electrical system STARTER RELAY CHECK • Remove the seat as described in chapter C Superstructures. • Disconnect the relay from the support plate. • Disconnect the start-up relay connector. • Disconnect the cables from the negative pole of the battery to avoid short circuits during assembly. - 19 -...
  • Page 176 Electrical system • Disconnect the cables of the starter motor and the positive cable of the battery from the relay. Apply 12 volts to the terminals (1) and (2) of the relay and check the continuity between terminals B-M. Do not apply the battery voltage to the starter relay for more than five seconds to avoid overheating and therefore damaging the winding.
  • Page 177 Electrical system GEARCHANGE POSITION SWITCH The connector (1) of the gear position sensor is loca- ted on the left beneath the tank. Disconnect the connector of the gear position switch and check the resistance value, using a multitester, in the six gears as well as the idle position, as shown in the attached table.
  • Page 178 Electrical system Utilising a multi-tester, check the continuity as indica- ted in the table. Green Brown Black ON (Raised) OFF (Lowered) After the tests described above, whenever it is neces- sary to replace the switch, proceed as indicated in chapter B Maintenance. FUSES The fuses are situated on the left side of the motorcy- cle.
  • Page 179 Electrical system The charge fuse is situated under the seat, in the posi- tion indicated on the starter relay. To accede to this component it is necessary to remove the following parts: Spare fuse • The driver’s seat; • Remove the plastic covers on both fuses. •...
  • Page 180 Electrical system Check the resistance between the electrode and the screw cap of the spark plug as shown in the figure. Permitted resistance: 4.5 ÷ 5.5 K Carry out the test on all the spark plugs. Do not use non-resistive spark plugs.. MAIN RELAY The main relay is situated on the left side and it is iden- tified by the “M”...
  • Page 181 Electrical system ENGINE PICK-UP The engine pick-up is situated on the left side of the motorcycle. To check this component it is necessary to identify the relative connector positioned as shown in the figure, inside the frame on the left side of the motor- cycle.
  • Page 182 Electrical system TIMING WHEEL GAP To guarantee the correct functioning of the pick-up it is necessary to measure the gap between the pick-up and the timing wheel by utilising a feeler gauge as shown in the figure. Gap width: 0.6 – 0.7 mm To carry out this check it is necessary to remove the cover of the timing wheel by consulting the Workshop Engine Manual.
  • Page 183 Electrical system Remove the connector holding device. With the switch in the “RUN” position, check the conti- nuity between pins (5) and (2). INSTRUMENTATION If faults are found in the instrumentation, it is necessary to check the main wiring and the various components assisted by the same instrumentation.
  • Page 184 Electrical system Consult the diagram below to identify the contacts of 16 pin AMP 174975-2 the various components: Supply ID warning led 10 Oil pressure + CAN 11 Ignition key - CAN 12 Serial Tx 13 Serial Rx High beam 14 Immobilizer Fuel warning led 15 Immobilizer...
  • Page 185 Electrical system Having ascertained the good condition of the fuses in question, proceed as follows: With the fuel tank removed from the motorcycle and empty of fuel, connect a small circuit composed of 12V battery and a light bulb of 12V – 1.7W to the connector of the fuel level indicator as shown in the diagram.
  • Page 186 Electrical system STARTER RELAY ACTIVATION • With the engine cut-off switch in the RUN position, press and hold down the starter button and check if 12V is sup- plied between relay switch wires B/Y and O/Y. • If that is not the case, check if voltage is present between the B/Y wire and ground •...
  • Page 187 Electrical system SPEED SENSOR Whenever the speed is not indicated on the dashboard and the message SPEED SENSOR appears, proceed as follows: • Check the conditions of the fuse in position 1 on the fuse box. If the fuse in question is in good condition, proceed with the check of the speed sensor as follows: Keeping the sensor connected to the system and with the key in the ON position, using a tester, check that...
  • Page 188 Electrical system HIGH BEAM HEADLIGHT In the event that the driving beam does not work, check the conditions of fuse 2. If the fuse is ok, check the continuity of the left handle- bar control connector between positions 1 and 10 with the driving beam function selected.
  • Page 189 Electrical system After having checked the bulbs of the headlight, the rel- ative fuses and the controls as described herewith, proceed with checks of the relays mounted on the left side of the motorcycle. TURN INDICATORS In the event that turn indicators do not work, check the conditions of fuse 1 on the fuse box.
  • Page 190 Electrical system LICENCE PLATE LIGHT If the number plate light bulbs do not function, check the condition of fuse 1 in the fuse box; if these are ok, replace the bulb. • Extract the light bulb holder. • Extract the light bulb. •...
  • Page 191 Electrical system If the relay is in good condition but is not energised aboard the vehicle, disconnect the connector on the temperature sensor. Make a bridge between the two contacts as shown in the figure. With the key in the ON position, after just a few seconds the fans should start rotating.
  • Page 192 Electrical system SWITCHES Check the continuity of each switch with a tester. If there is any anomaly, substitute the respective switch unit with a new one. R.H. switch L.H. switch - 36 -...
  • Page 193 Electrical system POSITIONING OF ELECTRICAL SYSTEM WIRE CLAMPS LIST OF FASTENING CLAMPS FOR F4 1000 ELECTRICAL SYSTEM CABLES ELENCO FASCETTE PER FISSAGGIO CAVI IMPIANTO ELETTRICO F4 1000 Code Qty. Length Name Codice Lunghezza Denominazione 800092248 800092248 L = 82 mm...
  • Page 194 TPS cable del nodo e del cavo TPS For the position of the clamps for fastening electri- cal system F4 1000 cables, refer to the layout Per il posizionamento delle fascette relative al fissaggio dei cavi dell’impianto elettrico F4 1000, shown below (see figs.
  • Page 195 Electrical system Note: Be careful N.B.: Prestare attenzione to correctly pass al corretto passaggio cables dei cavi Code Cod. 800092247 – L= 62 Code Cod. 800092248 – L= 82 Fig. 05 Note: Be careful N.B.: Prestare attenzione to correctly pass al corretto passaggio cables dei cavi...
  • Page 196 Electrical system Code Code Cod. 800092248 Cod. 800092248 – L= 82 – L= 82 Code Cod. 800092248 – L= 82 Fig. 06 Note: Be careful to ensure N.B.: Prestare attenzione correct assembly phasing alla corretta fasatura di of the cable lug montaggio del capocorda Note: Be careful N.B.: Prestare attenzione...
  • Page 197 Electrical system Fig. 08 Fig. 07 Code Cod. 800092247 – L= 62 Note: Position the N.B.: Posizione nodo branching node on the di diramazione sul right side of the frame lato dx del telaio Note the correct passage of vacuum gauge tubes on both the left and right sides of the Prestare attenzione al corretto passaggio dei tubi per il vacuometro sia sul lato sx che sul motorcycle (see figs.
  • Page 198 Electrical system - Position 1 adhesive protection code 8000B4924 on the front right side frame tube, first - Posizionare N° 1 protezione adesiva cod. 8000B492 4 sul tubo ant. telaio lato dx applying the upper edge as shown in Fig.11. applicandone inizialmente il bordo superiore come mostrato in Fig.
  • Page 199 Electrical system Screw cap Code Fig. 13 Cod. 800092248 Code Cappuccio per vite Cod. 800092247 (Code 800094896) – L= 82 – L= 62 (Cod. 800094896) Note: be N.B.: prestare careful to correctly attenzione al corretto pass cables passaggio dei cavi Note: Be careful to N.B.: Prestare attenzione Code...
  • Page 200 Electrical system Fig. 16 Code Cod. 800092247 – L= 62 Note: Be careful N.B.: Prestare to correctly pass attenzione al cables corretto passaggio Note: Be careful N.B.: Prestare dei cavi to correctly pass attenzione al corretto passaggio cables Code Cod. 800053724 dei cavi –...
  • Page 201 Electrical system Fig. 19 Fig. 20 Code Cod. 800092668 – L= 25 Code 800056783 Cod. 800056783 (plastic) (plastica) Code Cod. 800092247 – L= 62 3-way rear Connettore headlight AMP AMP 3 vie Fig. 22 fanale post. connector Code 800056783 Rear indicator + Cod.
  • Page 202 Electrical system Note: Be careful to N.B.: Prestare correctly pass attenzione al corretto Code Cod. 800092248 cables passaggio dei cavi – L= 82 Code Cod. 800092247 – L= 62 Note: Position the N.B.: Posizionare il wiring node at the Code Cod.
  • Page 203 Electrical system Note: Be careful N.B.: Prestare to correctly pass attenzione al cables corretto passaggio dei cavi Fig. 27 Note: Be careful N.B.: Prestare to correctly pass attenzione al cables corretto passaggio dei cavi Fig. 28 - 47 -...
  • Page 204 Electrical system - 48 -...
  • Page 205 Suspension and wheels SECTION Revision 0 - 1 -...
  • Page 206 Suspension and wheels SUMMARY FRONT WHEEL ..............PAGE 3 FRONT FORKS .
  • Page 207 FRONT WHEEL N·m 20 ÷ 22 40 ÷ 44 Torque Kg·m pressure ft·lb Operation Description F4 1000 FRONT WHEEL Material Aluminium alloy Dimensions 3,50” x 17” FRONT TYRE Dimensions 120/70-ZR 17 (58W) Brand and type PIRELLI - Diablo Supercorsa SP...
  • Page 208 Suspension and wheels FRONT WHEEL REMOVAL Place the motorcycle on the rear stand. Special tool N. 800092642 Front brake caliper removal Unscrew the two fixing screws of both front calipers and remove the calipers. Torque pressure: 40 ÷ 42 N·m Protect the disassembled calipers with pro- tective material thereby avoiding possible damage to the wheel rim.
  • Page 209 Suspension and wheels Remove the screw on both front wheel/fork attach- ments. During this operation, it is necessary to support the wheel. Open the terminals (1) and remove the wheel with its spindle. Front wheel bearing check With the wheel spindle still mounted to the wheel, rotate the wheel to check that the bearings are not pit- ted and rotate with a smooth action.
  • Page 210 Suspension and wheels Utilise the special tool to extract the bearings. To assemble the tool, it is necessary to remove the screw (1) and extract the wheel spindle (2). Remove the nut (3) and then the flange (4). Before substituting the bearings as indicated above it is advisable to remove the brake discs as indicated in chapter H “Brakes”...
  • Page 211 Suspension and wheels Check that the ends of the aluminium spacer and the seats of the bearings on the wheels are not scored or marked. Reassembly – front wheel bearings Before proceeding with the reassembly, accurately clean the bearing seats in the wheel hub. Lubricate the outer ring of both bearings with special grease.
  • Page 212 Suspension and wheels Insert it on the opposite part, keeping the rim in a verti- cal position. 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 213 Suspension and wheels Wheel spindle check Place the wheel spindle on two v-prisms on a flat sur- face. Utilising a dial gauge, check that the eccen- tricity in the central part does not exceed 0.05 mm. Wheel assembly If the front tyre is substituted, before assem- bling the wheel it is necessary to balance the wheel following the indications in page 77.
  • Page 214 8 ÷ 10 8 ÷ 9 16 ÷ 18 22 ÷ 24 Torque Kg·m pressure ft·lb Operation Description F4 1000 FRONT SUSPENSION Type “Upside down” telescopic hydraulic fork with external and separated adjustment of rebound and compression damping and of spring preload Ø stems (mm) Telescopic movement (mm)
  • Page 215 Suspension and wheels FRONT FORK OVERHAUL Before removing and overhauling the front suspension components, it is advisable to remove the lower fairing, the left and right fairings, the front cowl, the air ducts, the front mudguard, the spoiler, the left and right wire harness covers and the side panels as described in detail in the chapter “Fairings”.
  • Page 216 Suspension and wheels Stem removal Slacken the screw (1) of the steering head and the three screws (2) of the steering base. During this phase, support the stem. Slide out the stem, supporting it with both hands and operating with caution so as not to drop it. Proceed with the same operation for both stems.
  • Page 217 Suspension and wheels Completely unscrew the plug and lower the sheath as shown in the figure. Perform this operation while hold- ing the leg in a vertical position. Unscrew the plug. Using the spanner, adjust the spring preload while locking the nut on the damping piston rod.
  • Page 218 Suspension and wheels Remove the spring together with the spacer. Remove the inside rebound adjusting rod. Turn the stem upside down and completely pour out the oil into a suitable container. Recover the oil in an appropriate container. Do not dispose of the used oil in the environ- ment.
  • Page 219 Suspension and wheels Pull out the damping piston. Take care not to reverse the pumping elements on the fork while fitting it back in, and configure as follows: - Brake-pressing pumping element: fit on left fork. - Brake-releasing pumping element: fit on right fork. Lower dust cap (1), taking care not to damage the seat on the sheath.
  • Page 220 Measure the length of the spring and compare with the following values: - F4 1000: 260 mm Manually widen the upper bush and extract it. Remove the lower bush, the washer, the oil seal, the stop ring and the anti-dust seal (see figure).
  • Page 221 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 222 Check that the oil is at level "X" with reference to the upper sheath rim, measured when the sheath is com- pletely compressed. - F4 1000 (**): X = 70 mm (**): N.B.: Measured with the pumping rod at the end of its stroke and the spring spacer in.
  • Page 223 Suspension and wheels Manually turn the counternut in to the end of the threaded portion. The counternut is characterized by a special fitting direction. Ensure that the two span- ner resting surfaces are facing up (see fol- lowing figure). Fit in the spring. Fit the spanner to damping piston nut (1), pressing down slightly on the spring.
  • Page 224 (between the stem and the steering head). To ensure proper positioning of the rods, refer to the figure at right, taking care to observe fitting dimension "X": - F4 1000: X = 212 mm - 20 -...
  • Page 225 Suspension and wheels Screw in and tighten the three screws (1) at the base of the steering. Carry out this assembly correctly. A casual or inexact assembly could compromise the sta- bility and steering of the motorcycle. Fit the right-hand leg following a similar procedure. Tighten the three screws (1) at the base of the steer- ing.
  • Page 226 Suspension and wheels Assembly clip-on handlebars Position the electrical wiring as shown in the figure. Ensure that the Seeger retaining ring (1) of the clamp pin is in good condition and in position. Assemble the clip-on handlebar slotting the clamp pin into position on the steering head (see figure).
  • Page 227 The front fork is vitally important for the handling and stability of the motorcycle. It is therefore necessary to substitute the fork oil at the prescribed intervals. Quantity oil: - F4 1000: 720 cc (*) (*): approximate quantity calculated in relation to the actual maintenance level...
  • Page 228 Spring preload Rebound damper - Compressed brake: Turn clockwise to end stroke, then turn counter-clockwise until you hear the first click. Type of set-up F4 1000 On road On race track Spring preload 2 turns 5 turns Compression damper...
  • Page 229 Suspension and wheels STEERING ASSEMBLY N·m 120 ÷ 125 16 ÷ 18 8 ÷ 10 4 ÷ 6 22 ÷ 24 22 ÷ 24 8 ÷ 10 Torque Kg·m pressure ft·lb Operation - 25 -...
  • Page 230 Suspension and wheels STEERING ASSEMBLY OVERHAUL Lift the motorcycle and rest it on the special tool. Special tool No. 8000B4417 Steering head removal After having removed the two fixing screws (1) of the steering shock absorber on the frame, loosen the three fixing screws (2) of the steering head.
  • Page 231 Suspension and wheels Then remove the steering head complete with shock absorber and ignition key switch. Protect the steering head with padded material and rest it over the dashboard. Steering base removal Preliminary operations: - Disconnect the connectors (1) of the acoustic war- ning signal;...
  • Page 232 Suspension and wheels - Disassemble the handlebars and rest them on the front support, after having protected them with pad- ded material. Using the specific tool, loosen the ring nut of the stee- ring spindle, supporting the base of the steering head with a hand.
  • Page 233 Suspension and wheels Remove the anti-dust seal, the internal bearing ring and the ball bearing ring. Disassembly of the frame head steering sleeve Utilising the special tool, remove the steering screw ring. Special tool No. 800092857 Attention: During this operation press the centre of the tool with the palm of the hand.
  • Page 234 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 steering sleeve (see figure) and the threaded part with Agip Grease 30.
  • Page 235 Suspension and wheels Screw ring assembly After having accurately cleaned the screw ring and the seats of the steering head on the frame, grease the screw ring and screw it in manually onto the relative seat. Grease only the first threads and the conical section of the ring nut.
  • Page 236 Suspension and wheels Fit the lower triple clamp to the frame. Fit the upper ball bearing race after greasing it. Fit the bearing inner race, the dust seal and the upper clamping collar. Steering pin tightening Screw down, without tightening, the screw ring of the steering pin.
  • Page 237 Suspension and wheels Open the plastic clamp (1) on the right side of the headlight support frame and remove the wiring. Extract the ignition block connector (2) from the faste- ning plate and disconnect it. Remove the wiring from the left part of the motorcycle. - 33 -...
  • Page 238 Suspension and wheels Remove the complete steering head from the motorcy- cle. Remove the 2 key switch fixing screws and extract them. When reassembling, apply the following tightening torque: 22 ÷ 24 N·m Steering shock absorber connecting rod removal Remove the locknut of the screw (1) that connects the connecting rod to the steering head.
  • Page 239 Suspension and wheels Remove the screw (3) that connects the connecting rod to the steering shock absorber. Check that the connecting rod is in good condition and that play is not present on the two bearings. If play is found, substitute the worn parts with new ones.
  • Page 240 Suspension and wheels Steering head assembly Position the steering head in its housing according to the inverse order of disassembly operations. Tighten the central fixing screw (1) of the steering head. 22÷24 N•m Torque pressure: 22 ÷ 24 N·m Tighten the two front fixing screws (2) of the steering head.
  • Page 241 45 ÷ 50 70 ÷ 75 Torque Kg·m pressure ft·lb Operation Description F4 1000 REAR SUSPENSION Type Progressive, single shock absorber with rebound-compression (high speed/low speed) damping and spring preload adjustment Swingarm Aluminium alloy Wheel travel (mm) During the disassembly and check of the rear suspension assembly, it is advisable to disassemble the under- engine fairing, fairing side panels, tail unit and fuel tank as described in chapter C "Bodywork".
  • Page 242 Suspension and wheels Rear shock absorber disassembly Remove the seats, side panels, tank and rear panels as described in Chapter C "Fairings". Lift up the rear part of the motorcycle (with the specific lifter) high enough to take the load off the shock absorber.
  • Page 243 Suspension and wheels Remove the previously loosened upper screw. Remove nut (3) from the central rocker pin. Remove the pin (4) of the compensator assembly (5). - 39 -...
  • Page 244 Suspension and wheels Lift the rocker and extract at the same time as the com- plete shock absorber. Rear shock absorber test Check that the lower and upper bolt holes do not have axial (A) and radial (B) play. - 40 -...
  • Page 245 Suspension and wheels Check the length of the rear shock absorber spring. Standard spring adjustment (A): - F4 1000: A = 170,5 mm Check the functioning of the adjusters. The shock absorber contains high-pressure gas. Do not touch the valve of the shock absorber tank.
  • Page 246 Suspension and wheels Compensator assembly removal Remove the special screw (1) that fixes the compen- sator assembly of the rear suspension to the mono- arm fork. Extract the complete compensator assembly. Compensator assembly overhaul Remove the anti-dust seal (1). Check the condition of the roller bearings and if it is necessary to substitute them, utilise an extractor as shown in the figure.
  • Page 247 Suspension and wheels Rear shock absorber support plate removal Remove the three screw (1) indicated in the figure and remove the support plate (2). When reassembling, it is necessary to apply special product to the three screws and lightly screw them in. Tighten the central screw first and then the other two to the prescribed torque pressure.
  • Page 248 Suspension and wheels After having cleaned and greased the seat of the spe- cial screw situated on the mono-arm fork. Screw in the screw without tightening it. Recommended grease: Agip Grease 30 Rear shock absorber assembly Accurately clean all parts. Grease the screws with Agip Grease 30 before reassembly.
  • Page 249 Suspension and wheels SWINGARM REMOVAL AND OVERHAUL Remove the shock absorber and the con-rod of the rear suspension as described in the previous pages. Rear wheel removal Remove the rubber and the safety spring clip (1) and unscrew the screw ring of the wheel. Attention! The screw ring has a left-handed thread.
  • Page 250 Suspension and wheels Lower chain guard removal Remove the three socket head screws (1) of the lower chain guard. Remove the lower chain guard, taking care to recover the internal bushes. Exhaust protection removal Remove the three screws (1) that fix the protection onto the exhaust group.
  • Page 251 Suspension and wheels Extract the wiring and disconnect the three rear head- light connectors. Remove the fixing screw (1) of the exhaust valve plate. Loosen the lock nuts (2) of the valve opening and clo- sing adjusters. - 47 -...
  • Page 252 Suspension and wheels Remove the valve safety plate (1). Disconnect the valve opening and closing adjuster cables. Loosen the screws (2) from the exhaust connection clamp. - 48 -...
  • Page 253 Suspension and wheels To facilitate silencer dismantling operations, remove the rear fixing screw from the central protection. Move the rear end outward. Supporting the silencer unit in its rear part, remove the two exhaust support side screws (1) (see figure). Lower the rear part of the silencer unit by removing the heat guard wiring.
  • Page 254 Suspension and wheels Remove the silencer unit from the exhausts. Upper chain guard removal Remove the screw complete with ferrule. Extract the chain guard by pulling it out from the back part of the wheel (see figure) so that it is freed from its position on the swingarm.
  • Page 255 Suspension and wheels Unscrew shoulder bolt (2) until you can insert the chain into the special tool. Position the chain breaker (1) so that the ends of the chain pin can fit into the holes of the hex nut and bolt (2). Thread with the fingers the shoulder bolt (2) to put in phase the chain with the tool.
  • Page 256 Suspension and wheels Check that the fork of the new connecting link fork has an O-Ring installed on each pin. Insert the new connecting link fork from the wheel side, avoiding any contact with the pins in order not to remo- ve the lubricant.
  • Page 257 Suspension and wheels Riveting Use the professional rivet tool. Special tool no. 8000B1457. Pull the plate (4) to open the positioning rods (3), insert the chain into the tool in correspondance of the first pin to rivet an release the plate (4). The chain should be correctly inserted into the tool and kept in place by rods (3).
  • Page 258 Suspension and wheels Removing the rear brake caliper Loosen the two screws (1) and remove brake caliper (2). Speed sensor cable disassembly Remove the speed sensor cable holding clamp (3). Disconnect the speed sensor cable connector. - 54 -...
  • Page 259 Suspension and wheels Swingarm pin removal Before removing the swingarm pin, loosen the suspen- sion rocker pin and the two engine pins. Remove the screw (1) on the left side of the vehicle. Remove the washer and push out the pin manually. Support the swingarm so that it does not drop to the ground.
  • Page 260 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 261 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. Fitting the bearings and the roller cases on the rear swingarm.
  • Page 262 Suspension and wheels Utilising a press fit the bearings and the roller bearing units (see figure). - 58 -...
  • Page 263 N·m 30÷35 20÷22 45÷50 200÷220 28÷32 220÷240 140 5÷7 18÷20 Torque Kg·m pressure ft·lb Operation Description F4 1000 REAR WHEEL Material Aluminium alloy Dimensions 6,00” x 17” REAR TYRE Dimensions 190/55-ZR 17 (75W) Brand and type PIRELLI - Diablo Supercorsa SP...
  • Page 264 Suspension and wheels Before checking and overhauling the rear wheel hub assembly it is necessary to carry out the following pre- liminary operations: Place the motorcycle on the rear stand. Special tool no. 800092642 Remove the rear wheel by removing the polygonal nut. Utilise the following tools: •...
  • Page 265 Suspension and wheels Slacken the nut of the flange by rotating it in an anti- clockwise direction as shown in the figure. Utilise the following tools: • Torque wrench • 55 mm polygonal spanner Slacken the fixings (1) of the wheel hub. Remove the screw complete with bushing.
  • Page 266 Suspension and wheels With the special spanner mounted on the extension tube, pull forward the eccentric adjuster and release the chain from the crown wheel. Special tool: Eccentric adjuster spanner N. 800092854 Spanner extension N. 800092855 When adjusting the tension of the chain it is necessary to carry out the motorcycle set up adjustment.
  • Page 267 Suspension and wheels Remove the rubber clamp (1) around the rear brake pipe. Slacken the two screws (6) and remove the brake cali- per (7). Disassembly of the wheel pin Remove the wheel spindle complete with the brake disc, extracting it from the right side of the motorcycle as shown in the figure.
  • Page 268 Suspension and wheels Brake caliper support flange removal Remove the Seeger retaining ring (1), the spacer ring (2), the flange (3) and the spacer ring underneath. Wheel hub disassembly Extract the wheel hub from the left side of the fork. Carefully wash all parts.
  • Page 269 Suspension and wheels Caliper holder pin 30÷35 N•m Unscrew the caliper holder pin only if it is NOTE damaged. When reassembling apply the prescribed type of Loctite and tighten to the prescribed torque pressure. Recommended thread-locking fluid: Loctite Caliper holder pin torque pressure: 30 ÷...
  • Page 270 Suspension and wheels Check the extra-smooth parts of the wheel spindle for wear (A). Utilising a press with an adequate punch for both the removal and assembly of the pins of the wheel drive engagement. When assembling, apply force on the crown of the peg not on the point.
  • Page 271 Suspension and wheels Evaluate the wear condition of the crown wheel. If it is badly worn, effectuate a substitution with a new part proceeding as described. Extract the 5 spring drives (2) from the gear flange sup- port (3) and assess its condition. If the spring drives are worn, replace with new ones.
  • Page 272 Suspension and wheels Remove the 5 nuts (3) to free the crown (1) from the crown flange (2). Replace the crown. Remount the new crown on the crown flange, making sure the pins (4) enter the holes. Check that the coupling bushes of the gear flange sup- port (1) and the driving flange (2) do not show any signs of excessive or uneven wear.
  • Page 273 Suspension and wheels To assemble the brake caliper-carrying flange, carry out the following operations: Grease the O-rings and insert them into their respecti- ve seats on the flange. Assemble the rear spacer ring in contact with the hub, then the brake caliper-carrying flange (1), the second spacer ring and the Seeger retaining ring (1).
  • Page 274 Suspension and wheels Reassemble the brake caliper (1) and tighten the fixing screws (2) at the specified torque. 18 N•m Special product: Loctite 243 Torque pressure: 18 N•m Reinsert the rubber clamp (1) around the rear brake pipe. Insert the spacer with neck illustrated in the figure onto the wheel pin.
  • Page 275 Suspension and wheels Tighten the 5 nuts to block the silentblocks as shown in the figure. 25 N•m Tightening torque: 25 N·m Apply grease only on the threaded part Reposition the nut of the flange (1) with the relative washer (2) without tightening. Using the special spanner, bring the eccentric back into position by rotating in an anti-clockwise direction to tighten the chain.
  • Page 276 Suspension and wheels Tighten the wheel pin fixing nut by rotating it clockwise as shown in the figure, by using the following tools: • Torque wrench • 55 mm polygonal socket wrench Slip flange nut coupling torque: 200-220 Nm Apply grease only on the threaded part Assemble the retaining ri ng (1).
  • Page 277 Suspension and wheels Remove the screw (1) of the clutch control cylinder and the three screws (2) of the pinion wheel cover. Remove the cover being careful to not extract the clut- ch control rod (it must remain inserted in the engine) and be careful to not lose the two centralising bushes indicated in the figure.
  • Page 278 Suspension and wheels Using the specially designed spanner, remove nut (1) and washer (2). Remove the pinion and replace it with a new pinion. For reassembly, insert the pinion to end stroke. Take a new washer, assemble it with the nut and tight- en to the prescribed torque pressure utilising Loctite thread-locking fluid.
  • Page 279 Suspension and wheels MOTORCYCLE SET-UP ADJUSTMENT Place the motorcycle on the rear stand. Special tool no. 800092642 WARNING: The following adjustments must be made when the fuel tank is full. Insert the setting-up arm (1) of the rear suspension (special tool) in its appropriate seats as shown in the figure.
  • Page 280 Suspension and wheels Using an Allen key, change the centre distance between the two half linkages by turning adjuster (3). Repeat these operations until X is equal to the refer- ence dimension. Manually and firmly tighten the two tightening lock nuts of the half supports until you hit the adjuster bar.
  • Page 281 Suspension and wheels Measure the distance X between the upper end of the stand tube and the point on the setting rod indicated by an arrow (see figure). Δ Calculate static settling using the following formula: Δ 1 – The static settling value should be: Δ...
  • Page 282 Suspension and wheels WHEEL BALANCE CHECK If the tyres are substituted, it is necessary to effectua- te the following operations balancing and checking the wheels. Front wheel balancing Mount the wheel onto an adequate support similar to that shown in the figure, utilising a ground pin of 35 mm diameter.
  • Page 283 Suspension and wheels Insert the polygonal nut of the balancing tool from the opposite side and screw it onto the threaded part of the tool so that the tool can be fixed to the wheel. Mount the wheel onto an adequate support similar to that shown in the figure, utilising the special tool cod.
  • Page 284 Suspension and wheels When effectuating balancing on certain makes of tyres, it is necessary to refer to the yellow mark (1) present on the side of the tyre as shown in the figure. It indicates the lighte- st point of balancing and must be situated close to the tyre valve when the tyre is moun- ted onto the wheel rim.
  • Page 285 Frame SECTION Revision 1 - 1 -...
  • Page 286 Frame SUMMARY BATTERY CABLES ..............PAG. 3 REMOVAL OF SAS VALVE .
  • Page 287 Frame BATTERY CABLES It is a good rule to disconnect the battery cables before removing components from the motorcycle. After having removed the tail unit and the tank as described in chapter C "Superstructures," remove the fixing screws of the seat/tank support on both sides and remove the bracket.
  • Page 288 Frame Remove the battery from its compartment. If the power cables need to be removed, remove the battery, then, as described before, remove the fixing between the grounding wire and the engine. - 4 -...
  • Page 289 Frame SAS VALVE DISASSEMBLY This operation is only necessary if the engine should need to be removed from the frame. Disconnect the SAS valve connector (1). Remove the clamps and the tubes from the blade cov- ers. Remove the valve (2), pulling it from the support out- ward from the right side with the aid of a screwdriver.
  • Page 290 Frame Remove the SAS valve support fixing screws (3) and disassemble the support. If the SAS valve tubes must be removed, when reassembling be careful to correctly phase the clamps to prevent interference with their supports (see figure). - 6 -...
  • Page 291 Frame SIDE STAND REMOVAL If the side stand needs to be replaced, use the follow- ing procedure: Place the motorcycle on the rear stand (special tool). Special tool No. 800092642 Remove the side fairings and the underfairing as described in the chapter "Superstructures." Disconnect the electrical connector of the safety switch.
  • Page 292 Frame FOOTREST REMOVAL Unscrew the two screws (1) of both footrest supports and remove them. EXHAUST SILENCERS DISASSEMBLY Remove the closing wiring cover on the heat guard, levering with a screwdriver. Extract the wiring and disconnect the three rear head- light connectors.
  • Page 293 Frame Remove the fixing screw (1) of the exhaust valve plate. Loosen the lock nuts (2) of the valve opening and clos- ing adjusters. Remove the valve safety plate (1). - 9 -...
  • Page 294 Frame Disconnect the valve opening and closing adjuster cables. Loosen the screws (2) from the exhaust connection clamp. To facilitate silencer dismantling operations, remove the rear fixing screw from the central protection. Move the rear end outward. - 10 -...
  • Page 295 Frame Supporting the silencer unit in its rear part, remove the two exhaust support side screws (1) (see figure). Lower the rear part of the silencer unit by removing the heat guard wiring. Remove the silencer unit from the exhausts. - 11 -...
  • Page 296 Frame EXHAUST TUBE REMOVAL NOTE: This operation is not necessary for disas- sembly of the engine or frame. Proceed as descri- bed below for exhaust manifold replacement. Slide off the Lambda probe connector (1) and lift. Remove the central protection by unscrewing the two screws (2).
  • Page 297 Frame Unscrew the two screws (3), one per part, and remove the front protection. Unscrew the two nuts (4) relative to the manifold tube couple. Remove the nuts and fixing flanges (5). - 13 -...
  • Page 298 Frame Unhook the oil radiator from the rear support pin on the engine to then facilitate removing the manifold. Unscrew the rear support screw (6), holding up the manifold centrally. Remove the manifold as indicated in the figure. - 14 -...
  • Page 299 Frame Disassemble the ring seals (3) on the head. Apply sufficiently adequate wadding to the exhaust ports to stop the entry of dirt and dust into the cylin- ders. If the engine has to be removed from the frame, it will be necessary to remove the chain as described in chapter F “Suspension and wheels”.
  • Page 300 Frame FRAME REMOVAL PRELIMINARY OPERATIONS Support the motorcycle with the aid of the following kickstands: - Code 800092642: Rear kickstand - Code 800095807: Front kickstand - Code 8000B4303: Engine support Remove the following components in order: - Front mudguard - Front brake callipers - Front wheel - Central air manifold as described in chapters F - "Suspension and Wheels"...
  • Page 301 Frame THROTTLE BODY REMOVAL Remove the electrical connectors on the injectors (1) and on the potentiometer (2). Remove the phase sensor fixing screw (3). Remove the frame vacuum gauge sockets (4) on both sides of the vehicle and recover with adhesive tape. - 17 -...
  • Page 302 Frame Loosen to end stroke the screws (5) of the two pairs of clamps on the suction manifolds as shown in the figure. Loosen the upper gas control cable fixing nut (6). Disconnect upper cable from the support. - 18 -...
  • Page 303 Frame Loosen the lower gas control cable fixing lock nut (7). Remove the complete throttle body unit. Fully loosen the lower gas control fixing nut and remove from the throttle body. - 19 -...
  • Page 304 Frame Remove the clamp from the left suction manifold, move the phase sensor cable and the potentiometer cable to the side and fasten them to the frame with adhesive tape. Protect suction ducts with adhesive tape to prevent dirt intrusion inside the cylinders. Fully tighten the lower gas control fixing nut when reassembling the throttle body.
  • Page 305 Frame Check the proper passage of the connectors and tube as shown in the figure. Remove the following components in order: - Steering head - Acoustic warning signal - Right/left handlebars - Right/left front forks - Steering sleeve as described in chapter F - "Suspension and Wheels." - 21 -...
  • Page 306 Frame PLUG-TOP COIL DISASSEMBLY Remove the wiring fixing clamp on the right side of the frame. Disconnect the secondary air valve connector. Remove the coil fixing bracket screws. - 22 -...
  • Page 307 Frame Unhook the injection control unit and disconnect the coil cable connectors. Remove the coils pulling them upward. Turn coils on the outer side of the motorcycle before removing them. - 23 -...
  • Page 308 Frame Disconnect the two exhaust valve control cables from the actuator and remove them from the lower right part. Remove the two control unit fixing screws, sliding them toward the rear part and resting them on the engine. Wind the positive and negative electrical battery cables and position them on the engine.
  • Page 309 Frame Remove the engine rev sensor wiring clamp and dis- connect the connector. Remove the three Lambda probe wiring clamps. Disconnect the Lambda probe connector. Remove the Lambda probe wiring from the upper side of the motorcycle. - 25 -...
  • Page 310 Frame Disconnect the speed sensor and the rear stop con- nector. Disconnect the water temperature sensor connector. Disconnect the alternator connector. - 26 -...
  • Page 311 Frame Disconnect the gear sensor connector. Disconnect side stand switch connector. Disconnect the oil pressure sensor connector. - 27 -...
  • Page 312 Frame Slip the wiring of the two connectors that you just dis- connected behind the water pump tube and wind them on the frame hook present on the left side of the motor- cycle. Unscrew the two battery holder fixing screws on the right side of the motorcycle.
  • Page 313 Frame Disconnect the rear headlight connector. Disconnect the start-up remote switch. Slightly lower the battery holder from the right side and remove the rear frame electrical wiring. - 29 -...
  • Page 314 Frame Wind the wiring and fasten it on the control unit fixing clamp. FRAME DISASSEMBLY Unscrew and remove the right lower rear fixing nut from the frame. Remove the spindle from the left side of the frame. Unscrew and remove the upper rear fixing screws from both sides of the frame.
  • Page 315 Frame Unscrew and remove the engine fixing screw from the left side of the frame. Loosen the engine fixing screw from the right side of the frame without removing it. Remove the bushes from the rear right and left frame fixing points with the aid of a special tool.
  • Page 316 Frame Holding up the front part of the frame, remove the engine fixing screw from the right side of the frame. Remove the frame from the engine, taking care not to damage the electrical wiring. FRAME CHECKS AND INSPECTION Carefully clean the coupling bevel housing from the steering sleeve.
  • Page 317 Frame Check that no surfaces have any bumps or dents. Check that none of the area highlighted in the figure is deformed (as a result of any accidents). Check that there are no dents or evident breakage on frame tubes. Replace frame if any damage is detected.
  • Page 318 Frame - 34 -...
  • Page 319 Frame Steering sleeve housing check Check the diameter and for any ovalisation on the steering sleeve bevel housing, at 3 mm from the upper and lower edge as shown in the drawing here to the side. Measure ovalisation in different points as shown in the diagram.
  • Page 320 These components can be assembled on the new frame after having carried out a careful inspection. Contact MV AGUSTA spare parts service for approval punching and decals on the new frame. Carefully clean the frame-engine head and frame- rear suspension plates coupling planes.
  • Page 321 Frame Before proceeding with frame reassembly, replace the previously removed electrical wiring and components. - 37 -...
  • Page 322 Frame See Chapt. E - Electrical System regarding the posi- tioning and passage of cables, clamps and wiring. Preliminary wiring positioning operations on the engine To facilitate reassembly, before repositioning the frame on the vehicle, perform the following cable and tubing positioning checks.
  • Page 323 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 324 Frame - 40 -...
  • Page 325 Frame REAR FRAME DISASSEMBLY Remove the rubber caps from the upper fixing screws on the rear frame. Remove the four frame fixing screws. Hold the frame up before removing the last screw. Remove the rear frame from the vehicle. - 41 -...
  • Page 326 Frame FRAME PLATE REMOVAL Cut the chain as described in chapter F "Suspension and Wheels." Remove the exhaust manifold support screw from the right side of the motorcycle. Disconnect the rear brake pump connector. Remove the rear brake pump fixing screws. - 42 -...
  • Page 327 Frame Remove the rear brake pump and wind it with protec- tive material. Remove the gear control pedal. Remove the rear wheel fixing nut and disassemble the wheel. - 43 -...
  • Page 328 Frame Position an adequate support under the rear part of the motorcycle. Loosen the fork spindle pivot nut from the right side of the motorcycle. Partially slide the fork spindle pivot off from the left side of the motorcycle. - 44 -...
  • Page 329 Frame Remove the plate-rear suspension unit from the engine, moving it from the rear part of the motorcycle. Remove the rear brake fluid tank. Remove the rocker spindle fixing nut. - 45 -...
  • Page 330 Frame Remove the fork pivot spindle fixing nut. Remove the rocker spindle from the left side of the motorcycle. Remove the right frame plate. - 46 -...
  • Page 331 Frame Remove the fork pivot spindle from the left side of the motorcycle. Remove the left frame plate. REAR FRAME UNIT ASSEMBLY To assemble the rear sub-frame unit to the motorcycle, proceed in the reverse order of removal. Tighten the four fixing screws (1), two on each side, to the pre- scribed torque pressure.
  • Page 332 Frame ENGINE DISASSEMBLY FROM THE FRAME Support the motorcycle with the aid of the following kickstands: - Code 800092642: Rear kickstand - Code 800095807: Front kickstand - Code 8000B4303: Engine support Remove the following components in order: - Throttle body (page 17) - Secondary air valve (page 5) - Water radiator (chapt.
  • Page 333 Frame Disconnect the two exhaust valve control cables from the actuator and remove them from the lower right part. Remove the two control unit fixing screws, sliding them toward the rear part and resting them on the engine. Disconnect the coil cable connectors and remove them as shown in the figure.
  • Page 334 Frame Temporarily reposition the control unit on the frame, partially screwing in one screw. Remove the previously removed battery cable clamp and wind the cables themselves on the engine. Remove the wiring holding clamp on the right side and disconnect the rev sensor connector. - 50 -...
  • Page 335 Frame Disconnect the Lambda probe connector. Disconnect the complete rear brake pump, removing the two screws. Insert the rear brake pump in a protection cap, fixing it with an elastic on the frame. - 51 -...
  • Page 336 Frame Remove the screw and remove the gear pedal. Remove the four clutch cover fixing screws. Remove the cover holding the clutch control rod on the engine. - 52 -...
  • Page 337 Frame Protect the cover with a nylon cap and remove the two wiring holding clamps. Rest the cover on the handlebar. Break the chain as described in chapt. F "Suspension and Wheels" and remove the chain from the pinion. - 53 -...
  • Page 338 Frame Disconnect the kickstand connector and the oil pres- sure connector. Move wiring upward, winding it on the frame. Disconnect the gear sensor connector and the alterna- tor cable connector. - 54 -...
  • Page 339 Frame Disconnect the water temperature sensor connector. Loosen the fork spindle tightening screw, turning it once. Loosen the rocker spindle nut from the rear suspen- sion. - 55 -...
  • Page 340 Frame Remove the lower engine spindle nut. Extract the lower engine fixing spindle from the left side of the motorcycle. Remove the upper engine spindle nut. - 56 -...
  • Page 341 Frame Extract the upper engine fixing spindle from the left side of the motorcycle. Remove the front engine support screws (one per side). With a special tool, extract the bushes (one per side) of approximately 15 cm in order to free the engine. Special tool No.
  • Page 342 Frame Push the engine forward by hand approximately 3 cm. Lower the rear engine support screw in order to turn the engine downward. Lift the front part of the motorcycle by means of the rel- ative front kickstand crank. - 58 -...
  • Page 343 Frame Use the crank to free the engine. ENGINE ASSEMBLY ON THE FRAME To facilitate reassembly, before repositioning the engine on the vehicle, perform the following cable and tubing positioning checks. - Make sure that alternator and gear sensor connectors are in position (A).
  • Page 344 Frame Reposition the engine under the motorcycle. Lower the front part of the motorcycle by means of the relative front kickstand crank. Use the crank to align it for front engine fastening. This operation must be performed several times in order to prevent damage to the frame with the head- cylinder fixing screw.
  • Page 345 Frame Fully lower the front kickstand. Lift the rear engine support screw in order to turn the engine upward and realign with fixing holes. Insert the lower engine fixing spindle. - 61 -...
  • Page 346 Frame Rest the two front support screws (one per part). With a special tool, bring the engine centring bushes in position. Insert the upper engine support spindle. Make sure the wiring on the right side follows the direc- tion of the frame tubes. Perform all other remaining operations in the reverse order of disassembly, lubricating the various fasteners and tightening them to the torques detailed on page...
  • Page 347 Brakes SECTION Revision 0 - 1 -...
  • Page 348 Brakes SUMMARY FRONT BRAKE SYSTEM ............PAGE 3 FRONT BRAKE PADS SUBSTITUTION .
  • Page 349 16 ÷ 18 8 ÷ 10 23 ÷ 25 Torque Kg·m pressure ft·lb Operation Description F4 1000 FRONT BRAKE Type Dual floating disc with steel braking band Ø discs (mm) Disc flanges Aluminium Calipers (Ø pistons mm) Radial-type, single-piece with 4 pistons Ø 34 Front disc thickness (mm) Min.
  • Page 350 Brakes FRONT BRAKE PADS SUBSTITUTION To replace the front brake pads, remove the front brake caliper, as detailed in the “Suspensions and Wheels” section. Widen the pads with a screwdriver so that the pistons are pushed back into their seats (as shown in the fig- ure).
  • Page 351 Brakes Before fitting the pads back in, make sure the plate rests against its stop. If it does not, push it down, as shown in the Figure. Fit either pad through the midst of the front back caliper opening, then push it towards its pistons. Do the same with the other pad.
  • Page 352 Brakes SUBSTITUTION AND BLEEDING OF THE FRONT BRAKE FLUID Place the motorcycle on a horizontal surface with the steering in a straight line. It is advisable to remove the nose fairing when carry- ing out this operation. Remove the two screws of the front brake fluid cham- ber cover.
  • Page 353 Brakes Fill the system by pulling the front brake lever 3-4 times (see figure). Repeat the above operations until the fluid reaches the minimum level in the reservoir. Top up with fresh fluid and carry on with the operation until fluid of a different colour (fresh) flows out.
  • Page 354 Brakes Pour new brake fluid into the chamber until it reaches the maximum level. Recommended brake fluid: AGIP Brake Fluid DOT 4 Utilise only the prescribed brake fluid from sealed containers. NEVER use old or used brake fluid. Top-up the level of the fluid until it reaches the maxi- mum mark Carefully clean around the edge of the brake fluid chamber utilising a clean cloth.
  • Page 355 Brakes Accurately clean the three elements of the brake fluid chamber cap with alcohol and dry with compressed air. Place the cap on the brake fluid chamber and tighten the two lateral fixing screws. - 9 -...
  • Page 356 Brakes FRONT BRAKE CALIPERS SUBSTITUTION • 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. • Taking care to not spill any remains of the brake fluid that may remain inside the brake tubing, remove the union as indicated in the figure.
  • Page 357 Brakes Remove the connectors of the electrical system. Remove the fixing screw that fixes the pump to the handlebar. Open the clamp. Push down to remove the pump from the reference pin. REPLACING THE BRAKE FLUID RESERVOIR Loosen fixing screw (1) and then remove the brake fluid reservoir.
  • Page 358 Brakes Thoroughly clean housing (1). Fit O-ring (2) into its groove. Use a new O-ring. NOTE Place reservoir (1) in its housing (2). Insert rubber separator (3). Put a thread-brake of the recommended type on the first few threads of the locking screw (1). Specific product: Loctite 243 Insert the fixing screw (1) into the corresponding threaded hole and tighten the screw to the prescribed...
  • Page 359 Brakes REPLACING THE FRONT BRAKE SWITCH To replace 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 previ- ously described in this chapter.
  • Page 360 Brakes When reassembling, be careful to insert the pin of the pump piston into the seat situated on the lever (see figure). Grease the pin: Recommended grease: Agip Grease 30 For the reassembly of the lever tighten the pin. Tighten the nut while holding the pin in place with a flat blade screwdriver.
  • Page 361 Brakes FRONT BRAKE DISC REMOVAL Take down the front wheel as described in chapter F "Suspensions and Wheels". Using two special spanners (see chapter F "Suspen- sions and Wheels"), remove the front wheel spindle. Special tool 800092872 Place the wheel in a horizontal position and remove the five screws of each disc proceeding in a star-like mode for the removal.
  • Page 362 Brakes Front disc assembly Thoroughly clean the contact surfaces of the discs and the wheel. Accurately grease all relative surfaces of the disc before reassembling. The following operation is to be carried out on all mod- els. Apply thread-locking fluid to the five fixing screws of the disc.
  • Page 363 18 ÷ 20 16 ÷ 18 Torque Kg·m pressure ft·lb Operation Description F4 1000 REAR BRAKE Type Single steel disc Ø discs (mm) Caliper (Ø pistons mm) With 4 pistons Ø 25.4 Rear disc thickness (mm) Min. pads thickness (mm)
  • Page 364 Brakes REAR BRAKE PADS SUBSTITUTION Remove the safety retainer and unscrew the rear ring nut by turning it clockwise (see figure). Remove the wheel. Utilising circlip pincers as shown in the figure, widen the pads so that the pistons are pushed back into their seats.
  • Page 365 Brakes Remove the pad support pin (1) and the relative spring (2). Remove the pad (3) by letting it drop down. Carry out the check every 6000 kilometres. Brake disc Brake pads Check the condition of the rear braking system and its components.
  • Page 366 Brakes Tighten the pin to the prescribed torque pressure. Torque pressure: 15 ÷ 20 N·m 15÷20 N•m SUBSTITUTION AND BLEEDING OF THE REAR BRAKE FLUID The operation described herewith must be carried out with the engine cold because of the nearness of the exhaust tubes that could cause grave burns.
  • Page 367 Brakes Connect a rubber tube to the bleed valve, empty the system in an appropriate container by slackening the bleed valve as shown in the figure Tighten the bleed valve. Fill the rear brake fluid reservoir until the fluid reaches the maximum level.
  • Page 368 Brakes REAR BRAKE CALIPER SUBSTITUTION To facilitate the operation, remove the brake pads as described previously. Empty the rear brake system as previously described in the paragraph “SUBSTITUTION AND BLEEDING OF THE REAR BRAKE FLUID”. Remove the tubing by unscrewing the union indicated in the figure.
  • Page 369 Brakes Rear brake pump removal Carry out the emptying of the brake system as previ- ously described. Remove the clip with the pump control fork pin by turn- ing the pin and pulling it out (see figure). Unscrew connection (1) as shown in the figure so as to disengage the pump from the brake line.
  • Page 370 Brakes After having carried out a check on all components and substituted those used, damaged or defective proceed 16÷18 N•m with the assembly by following the procedure in reverse order of removal. Substitute the gaskets of the pump/caliper NOTE hoses. Tighten the fixings to the prescribed torque pressure.
  • Page 371 Brakes Check the planarity of the rear brake disc by utilising a micrometer gauge and placing the disc on a level work surface. Utilise the same procedure adopted for the front wheel discs. The planarity value must not exceed 0.3 mm. Utilise a micrometer gauge with support to carry out this check.
  • Page 372 Brakes - 26 -...
  • Page 373 Cooling system SECTION Revision 0 - 1 -...
  • Page 374 Cooling system SUMMARY COMPLETE COOLING SYSTEM ASSEMBLY ..........PAGE 3 COOLING SYSTEM LEAKAGE CHECK .
  • Page 375 Cooling system COMPLETE COOLING SYSTEM ASSEMBLY Before proceeding with the disposal or overhaul of any component relative to the cooling system, carry out cer- tain preliminary operations: 1) Let the engine cool down. 2) Remove the side fairings, the underfairing, the fairings push rod, the headlight fairing, the suction duct covers and suction ducts as described in the chapter "Superstructures."...
  • Page 376 Cooling system COOLING SYSTEM LEAKAGE CHECK Before removing the radiator and discharging the engine coolant, check that the cooling system does not have leakages. Remove the water radiator cap and connect the tester (of the type shown in the diagram) to the filler hole. Do not open the radiator cap whilst the engine is hot.
  • Page 377 Cooling system ENGINE COOLANT EXTRACTION Remove the water radiator cap. Open the cap of the expansion tank. Empty the cooling system of the coolant as follows: • Place under the engine a container to collect the dis- charged coolant. • Remove the discharge screw (1) situated on the water pump (2) •...
  • Page 378 Cooling system Disconnect the tension regulator connector from the left side of the motorcycle and remove the holding clamp. Disconnect the three clic holding clamps of the radiator tubes. Special tool: CLIC 205 pincers Disconnect the tubes. - 6 -...
  • Page 379 Cooling system Remove the upper and lower fixing screws of the radia- tor from the left side. Special tool: CLIC 205 pincers Remove the upper central radiator fixing screw. Holding the upper radiator (water), push the lower radiator (oil) toward the right to remove the connector pin.
  • Page 380 Cooling system Lower the left side radiator and push it toward the right to remove the upper support pin. Extract the radiator from the left side, turning it as shown in the figure. If necessary, to carry out overhauling of the lower water union tube, remove the two clic clamps at the end of the radiator filling tube on the left side of the motorcycle.
  • Page 381 Cooling system Remove the tube. Before carrying out this operation, position a collection container under the engine to collect any residual liquid. Carry out the said operations with care. NOTE Pour the remaining coolant inside the radiator into an appropriate container. Do not dispose of engine coolant in the envi- ronment.
  • Page 382 Cooling system WATER RADIATOR COMPONENT DISASSEMBLY Expansion tank removal Unscrew the expansion tank cap. Empty the tank in an appropriate container. Disconnect the clic holding clamp of the water radiator recovery tube and remove the tube. Special tool: CLIC 205 pincers - 10 -...
  • Page 383 Cooling system Remove the two radiator tray screws and remove the tray itself. Check for any tube faults. Tension regulator disassembly Remove the two tension regulator support fixing screws and remove the regulator. Electric fan disassembly Remove the central cable holding clamp. - 11 -...
  • Page 384 Cooling system Remove the two rigid clamps cutting them with clip- pers. Disconnect the two electric fan cable connectors. Remove the 6 fan rack fixing screws (3 per side) and remove racks. - 12 -...
  • Page 385 Cooling system Radiator fastening component disassembly. Remove the four threaded clips. Release the closing cap clic clamp and remove everything. Special tool: CLIC 205 pincers - 13 -...
  • Page 386 Cooling system Unscrew and remove the radiator anchoring pin. Remove the left upper support bracket spacer. Remove the upper support bracket vibration dampers. - 14 -...
  • Page 387 Cooling system RADIATOR GROUP ASSEMBLY Before reassembling, check the correct rotation of the fans, the condition of all components and all connec- tions. Radiator check and clean The dirt and extraneous material embedded in the radi- ators must be removed. It is recommended to use compressed air for the clean- ing of the radiator.
  • Page 388 Cooling system Tighten the 6 screws (3 per fan) to the prescribed tigh- tening torque. Torque pressure: 5 ÷ 6 N·m Replace the previously removed components following the disassembly procedures inversely. 5÷6 N•m Recovery tank fixing screws: 8 N•m Torque pressure: 8 N·m Recommended threadlocking product: Loctite 243 Radiator connection pin:...
  • Page 389 Cooling system The assembly of the new radiator group has been completed. At the end of the assembly operation, the radiator group should look like the group indicated in the figure. The radiator group can be mounted onto the motorcy- cle.
  • Page 390 Cooling system Check Check to see if the thermostat pad is damaged. Check the functioning of the thermostat as follows: • Suspend the thermostat by a piece of string threaded through the flange as indicated in the figure. • Immerse the thermostat in water contained in a labo- ratory glass as indicated in the figure.
  • Page 391 Cooling system THERMOSTAT ASSEMBLY Insert the O-ring (1) in its appropriate seat on the cover of the thermostat. Check the condition of the O-ring previously utilised. If the O-ring is not in good condition, substi- tute it with a new one. Apply a thin layer of silicone grease.
  • Page 392 Cooling system Insert the thermostat cover on the engine. Tighten the three fixing screws (1) to the prescribed torque pressure. Torque pressure: 10 N·m Replace the tubes on the thermostatic valve and fasten the relative clic clamps. 10 N•m WATER RADIATOR VEHICLE UNIT ASSEMBLY Insert the upper right radiator mount into the peg on the frame (right side).
  • Page 393 Cooling system OIL RADIATOR DISASSEMBLY Insert the receptacle under the engine and remove the oil drain screw. Proceed with emptying oil present in the engine. Remove the clamps from both sides of the central water tube with the aid of a screwdriver. - 21 -...
  • Page 394 Cooling system Remove the screws from the tube holding plate of the radiator and remove the plate. Remove the lower oil radiator support bracket. Move the tube support plate outward to facilitate the following operations. - 22 -...
  • Page 395 Cooling system Remove the tube unions from the right side of the oil radiator with the aid of a screwdriver. Remove the central water tube from the supports on the oil radiator. Remove the oil radiator support screw from the left side of the motorcycle.
  • Page 396 Cooling system Lower the oil radiator from the left side and push toward the right to free it from the support pin. Remove the oil radiator. Check the conditions of the component and, if neces- sary, straighten the folded flaps with a screwdriver. - 24 -...
  • Page 397 Cooling system OIL RADIATOR ASSEMBLY Before reassembly, check the integrity of the oil tubes and replace if necessary. Also check conditions of the oil tube union seal rings and replace if necessary. Grease O-rings with silicone grease. Reassemble previously removed components in the opposite order of disassembly.
  • Page 398 Cooling system FILLING THE COOLING SYSTEM Lift the front part of the motorcycle as shown in the figure. Fill the cooling system with a suitable liquid described in the table (see page B-8) until you reach the level of the bar of the radiator filler cap. Do this in stages to sta- bilise the liquid level.
  • Page 399 Cooling system MOTOR OIL SYSTEM FILLING Unscrew filler plug using the 10-mm hexagonal bar provided fitted to a specially designed spanner (see figure). Pour in the required quantity of oil. Check the level of oil in the appropriate window. Before replacing the filler plug, grease O-ring (1) with silicone grease, then reinsert it into its seat (see fig- ure).
  • Page 400 Cooling system SYSTEM FUNCTIONING CHECK Assemble the following components in order: • Airbox. • Fuel tank. • Rear side panels. • Fuel tank side panels. • Airbox side panels. For the assembly operations, assemble in reverse order of removal. Cooling system Insert the ignition key and start up the vehicle engine.
  • Page 401 Special tools SECTION Revision 1 - 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 F4 1000 Descrizione Description 800095830 • Cavalletto Front stand anteriore 800091645 • Chiave ghiera Steering bearing cuscinetti di sterzo pin wrench 800092857 • Chiave ghiera Steering cam eccentrico sterzo ring nut wrench 800092860 • Estrattore cuscinetti...
  • Page 404 Special tools - 4 -...
  • Page 405 Special tools Code Q.ty Note F4 1000 Descrizione Description 800092867 • Attrezzo montaggio Equaliser pacco bilanciere pack tool 8000B4421 • Attrezzo cuscinetti Front wheel ruota anteriore bearings tool 8000B1439 • Attrezzo taglio Chain cutting tool catena 8000B1456 • Attrezzo chiusura...
  • Page 406 Special tools - 6 -...
  • Page 407 Special tools Code Q.ty Note F4 1000 Descrizione Description 8A0094792 • Attrezzo montaggio Gear change cambio mounting tool 800086119 • Bussola di Locating bush riferimento 8000A1087 • Cuscinetto Bearing 800098405 • Cuscinetto Bearing 800087300 • Cuscinetto Bearing 8A00A5394 • Software...
  • Page 408 Special tools - 8 -...
  • Page 409 Special tools Code Q.ty Note F4 1000 Descrizione Description 8000B2114 • Software Power unit programmazione programming centralina software 8A00B2114 • Software Power unit programmazione programming centralina software 8000B2116 • Chiave USB USB key 8000B2117 • Cavo seriale Serial cable 8A00B2117 •...
  • Page 410 Special tools - 10 -...
  • Page 411 Special tools Code Q.ty Note F4 1000 Descrizione Description 8000B2051 • Attrezzo fissaggio Exhaust screw vite scarico fixing tool 800079015 • Attrezzo bloccaggio Clutch blocking tool frizione 8000A2280 • Attrezzo chiusura Timing chain catena distribuzione mounting tool 8000A2281 • Attrezzo apertura...
  • Page 412 Special tools - 12 -...
  • Page 413 Tightening torques SECTION Revision 1 - 1 -...
  • Page 414 Tightening torques - 2 -...
  • Page 415 Tightening torques - 3 -...
  • Page 416 Tightening torques - 4 -...
  • Page 417 Diagnostic SECTION Revision 0 - 1 -...
  • Page 418 Diagnostic ELECTRICAL COMPONENTS CHARGING SYSTEM Battery warning light on Alternator broken Replace Alternator connection defective Check Battery faulty Replace Recharge fuse (40A) blown Replace Recharge fuse connection defective Deoxidize/Repair Battery connections oxidized Deoxidize/Repair POWER SUPPLY FOR 12V SERVICES No function enabled Ignition switch broken Replace Ignition switch connection defective...
  • Page 419 Diagnostic Brake light does not work Fuse 1 blown Replace Fuse 1 connection faulty Deoxidize/Repair Device damaged Replace Front brake lever switch broken Replace Front brake lever switch connection faulty Deoxidize/Repair Rear brake lever switch broken Replace Rear brake lever switch connection faulty Deoxidize/Repair Brake light stays on Front brake lever switch jammed...
  • Page 420 Diagnostic IGNITION - INJECTION IAW 1.6M Air pressure/temperature sensor indicates malfunction Sensor broken Replace Sensor connection faulty Deoxidize/Repair Throttle valve potentiometer indicates malfunction Potentiometer broken Replace Potentiometer connection faulty Deoxidize/Repair Engine temperature sensor indicates malfunction Engine temperature sensor broken Replace Engine temperature sensor connection faulty Deoxidize/Repair FUEL INJECTION SYSTEM...
  • Page 421 Diagnostic FRAME STEERING Steering stiff Steering bearings damaged Replace Steering bearings overtightened Adjust Steering pin bent Replace Steering damper action excessive Adjust Steering damper joints damaged Replace Tyre pressure low Adjust Vehicle tends to steer or does not travel on a straight line Fork bent Replace Frame bent Replace...
  • Page 422 Diagnostic Swingarm bearings damaged Replace Swingarm rocker bearings damaged Replace Shock absorber joints damaged Replace Suspension linkage joints damaged Repair Swingarm pin bent Replace BRAKES Brake lever and pedal soft (“spongy”) Air bubbles in hydraulic circuit Bleed Leaks in hydraulic circuit Repair Caliper seals damaged Replace...
  • Page 423 Analytical index SECTION Revision 1 - 1 -...
  • Page 424 Analytical index ANALYTICAL INDEX - F4 1000 WORKSHOP MANUAL Transmission chain .....B-53 Tube band fasteners ....B-60 Section A - General Description Tyres .
  • Page 425 Analytical index Couplings ......E-3 Rear wheel hub ......F-59 Electrical diagram .
  • Page 426 Analytical index Section L - Cooling system Complete cooling system assembly ..L-3 Cooling system leakage check ... . .L-4 Electric fan removal .....L-11 Engine coolant extraction .

Table of Contents