MV Agusta F4 750 Instructions Manual
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MV Agusta F4 750 Instructions Manual

Cooling system
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Cooling system
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Summary of Contents for MV Agusta F4 750

  • Page 1 Cooling system SECTION Revision 0 - 1 -...
  • Page 2 Cooling system SUMMARY COMPLETE COOLING SYSTEM ASSEMBLY ......... .PAGE 3 COOLING SYSTEM LEAKAGE CHECK .

  • Page 3: Complete Cooling System Assembly

    Cooling system COMPLETE COOLING SYSTEM ASSEMBLY Before proceeding with the disposal or overhaul of any component relative to the cooling system, carry out cer- tain preliminary operations: 1) Let the engine cool down. 2) Remove the under-engine fairing, the left and right fairing side panels, the tail unit, the right and left side pan- els, the fuel tank and the air compartment as described in chapter C “Bodywork”.

  • Page 4: Cooling System Leakage Check

    Cooling system 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 expansion tank cap and connect the tester (of the type shown in the diagram) to the filler hole.

  • Page 5: Engine Coolant Extraction

    Cooling system ENGINE COOLANT EXTRACTION 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 6 Cooling system Disconnect the connector (1) of the ignition switch and remove the relative rubber band (2). Operate from the right side of the motorcycle. Lift up the ignition switch (1) and then remove it by slid- ing it backwards (2). Remove the connection tube shown in the figure.
  • Page 7 Cooling system To extract the tube it is necessary to free it from its fix- ings as indicated in the figure. Disconnect the radiator charging tube. Remove the band fasteners utilising the CLIC 205 pin- cers. Special tool: CLIC 205 pincers. - 7 -...

  • Page 8: Radiator Removal

    Cooling system Disconnect the overflow tube of the cooling system. Special tool: CLIC 205 pincers. Remove the expansion tank. RADIATOR REMOVAL Remove the band fastener of the thermostat connect- ing tube of the radiator. Special tool: CLIC 205 pincers. Remove the band fastener of the radiator tube/metal tube.
  • Page 9 Cooling system Suck out the residue coolant from inside the lower radi- ator. Disconnect the tube coming from the heat exchanger. Special tool: CLIC 205 pincer. Disconnect the connector of the water temperature sensor (1). - 9 -...
  • Page 10 Cooling system Disconnect the two connector of the electric fan (2) and (3) situated on the right side of the motorcycle. Remove the fixing screws of the radiator. Extract the screw and the flanged aluminium bush. The radiator is freed from its supports. N.B.

  • Page 11: Water/Oil Heat Exchanger

    Cooling system WATER/OIL HEAT EXCHANGER This device is to cool the engine oil. It functions by giving the heat of the oil to the water that it passes over. For the removal and overhaul of this part consult chap- ter “Engine”. ELECTRIC FAN REMOVAL Remove the two rubber band fasteners.

  • Page 12: Radiator Group Assembly

    Cooling system RADIATOR GROUP ASSEMBLY Before reassembling, check the correct rotation of the fans, the condition of all components and all connec- tions. As the two radiators have been separated, it is neces- sary to reassemble them in the following order: Radiator check and clean The dirt and extraneous material embedded in the radi- ators must be removed.
  • Page 13 Cooling system Insert the new electric cooling fan (1) onto the support frame (2). Tighten the fixing nuts (3) to the prescribed torque Torque pressure: 5 ÷ 6 N·m 5÷6 N•m Position the previously assembled electric cooling fan onto the upper radiator. 5÷6 N•m Tighten the screws (4) to the prescribed torque pres- sure.
  • Page 14 Cooling system Position the wiring of the upper electric cooling fan as indicated in the figure. Insert the electrical connector into its tongue support in the area indicated of the fan frame. Position a strap fastener (1) in the position indicated in the figure.
  • Page 15 Cooling system Insert the flanged bush (1) inside the anti-vibration rub- ber situated on the left side of the lower radiator. Assemble the two radiators. Insert the T.E.F. M6 L = 25 mm screw (1) and tighten. Assemble the rubber radiator connecting hose (1) as indicated in the figure.
  • Page 16 Cooling system Tighten the two CLIC R 96 300 (white colour) band fasteners. Special tool: CLIC 205 pincer Position the fastener band as shown in the figure. A different position of the head of the fastener could create interference with the fairing side panel. Insert the anti-vibration rubbers (1) (two for each side of the radiator) into their relative upper supports.
  • Page 17 Cooling system The following two phases apply ONLY to the following models: • F4 ORO • F4 S and F4 S 1+1 (up to frame registration num- ber 004611). Fix the electric lead of the lower radiator cooling fan to the support frame of the fan, utilising two strap fasten- ers (1) and position them as indicated in the figure.
  • Page 18 Cooling system In proximity of its first part the lead must be positioned at a minimum distance of 5 mm from the blades of the lower fan so as to avoid accidental damage to the lead when the fan is in operation. To avoid possible contact between the elec- min.
  • Page 19 Cooling system Insert the support complete with anti-vibration rubbers onto the cooling fan support of the lower radiator. 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 20: Coolant Temperature Sensor

    Cooling system COOLANT TEMPERATURE SENSOR If it is necessary to check the efficiency of the coolant temperature sensor, proceed as follows. Disconnect the electrical connector as shown in the fig- ure. Remove the coolant temperature sensor. Check Check that the resistance of the coolant temperature sensor varies with the temperature as shown.

  • Page 21: Fan Thermal Switch

    Cooling system Assembly Before assembling the sensor, apply Teflon tape onto the threaded section of the sensor. Tighten the coolant temperature sensor to the speci- fied torque pressure. Coolant temperature sensor torque pres- sure: 18 N·m Be careful when inserting the coolant tem- perature sensor.

  • Page 22: Thermostat

    Cooling system THERMOSTAT Removal Remove the three fixing screws (1) of the thermostat cover (2). Remove the cover of the thermostat (2). Remove the thermostat (3). - 22 -...
  • Page 23 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 24 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 25 Cooling system Insert the cover of the thermostat, complete with ther- mostat onto the engine. Tighten the three fixing screws (1) to the prescribed torque pressure. 10 N•m Torque pressure: 10 N·m Tighten the thermal switch of the electric fan (2) ensur- ing that the connector is in a vertical or horizontal posi- tion.

  • Page 26: Expansion Tank Assembly

    Cooling system EXPANSION TANK ASSEMBLY Position the tube in respect of the expansion tank as indicated in the figure. Position the expansion tank on the frame. Insert the engine coolant filler tube and the overflow tube inside the plastic clip. Place the tube close to a frame tube.
  • Page 27 Cooling system Fix the two rubber tubes to the frame as shown in the figure. To allow the correct assembly of the left fairing side panel and before fixing the rubber fastener, check that the placing of the components are as follows: RUBBER FASTENER FRAME TUBE OVERFLOW TUBE...
  • Page 28 Cooling system Tighten the fasteners indicated in the figure using the CLIC 205 pincer. Special tool: CLIC 205 Connect the radiator filler tube. Fix with a band fastener CLIC R 96 170 (black colour). Special tool: CLIC 205 Assemble the rubber protection band (1). - 28 -...

  • Page 29: Radiator Group Assembly To The Motorcycle

    Cooling system Make good the connection of the ignition switch, work- ing from the right side of the motorcycle. Fix the connector to the frame utilising rubber band fastener. RADIATOR GROUP ASSEMBLY TO THE MOTORCYCLE Assemble the radiator group to the motorcycle. Insert the thermostat/radiator connecting hose.
  • Page 30 Cooling system Insert the fixing screw of the radiator and tighten to the prescribed torque pressure. 10 N•m Torque pressure: 10 N·m Assemble the metal tube/lower radiator connecting hose. Ensure that the length of hose pushed onto the metal tubes is equal on both sides. Position the band fastener approximately 5 mm from the end.
  • Page 31 Cooling system Tighten the two band fasteners of the metal tube/radi- ator. Systemise the band fasteners so that the clip part is pointing downwards. Utilise band fasteners CLIC R 96 300 (white colour). Special tool: CLIC 205 pincer Connect the tube coming from the heat exchanger. Tighten utilising a band fastener CLIC R 96 145 (black colour).
  • Page 32 Cooling system Connect the tube for the discharging of the cooling sys- tem. Utilise band fastener CLIC R 96 120 (black colour). Special tool: CLIC 205 pincer Connect the two connectors of the fans situated on the right side of the motorcycle. Fix the electrical wiring to the frame with the relative rubber fasteners.

  • Page 33: Filling The Cooling System

    Cooling system Insert the pin for the fairing (1) and tighten the two lat- eral screws (2). The radiator group that has just been N.B. assembled should be complete with all parts as shown in the exploded view in page 2 of this chapter. Carry out a final check before proceeding with successive operations.

  • Page 34: System Functioning Check

    Cooling system Fill until reaching the MAX level indicated on the expansion tank. Close the cap. SYSTEM FUNCTIONING CHECK Assemble the following components in order: • Right air intake • Left air intake • Air filter compartment • Fuel tank For the assembly operations, assemble in reverse order of removal.
  • Page 35 Cooling system Check the level of oil in the appropriate window (2). Screw in the filler plug after having topped-up to the correct level. Insert the ignition key and switch on the motorcycle. Let it run for approximately one minute. Check carefully for leakages in the cooling system.
  • Page 36 Cooling system - 36 -...

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