MV Agusta 2008 F4 312RR 1078 Workshop Manual Download

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Crankcase

STARTING

OIL

Apply motor oil

NO OIL

Do not apply neither oil nor other types of substances

Apply grease

Apply silicone sealing

HSC

Apply HSC Molikote

Apply mastic for gaskets

N·m

Tightening
torque

Thread blockers

medium

strong

medium

Summary of Contents for 2008 F4 312RR 1078

Page 1: ......

Page 2: ...2008 The reproduction even partial of this document is forbidden without prior written agreement of MV Agusta S p A Part N 8A00B2576 Edition N 1 Printed October 2008...

Page 3: ...MVAGUSTA F4 312RR 1078 Workshop engine manual...

Page 4: ...e g the collection of spare parts the preparation of tools and equipment etc To reach the part to be repaired limiting the work to the essential operations With regards to this a valid help would be t...

Page 5: ...Freni 3 A B General Index GENERAL DESCRIPTION MAINTENANCE CYLINDER KIT CRANKCASE LUBRICATION ELECTRICAL COMPONENTS TIGHTENING TORQUES SPECIAL TOOLS ANALYTICAL INDEX C D E F G H I...

Page 6: ......

Page 7: ...1 General description A SECTION A Revision 0...

Page 8: ...RY HOW TO CONSULT THIS MANUAL PAGE 3 THE PURPOSE OF THIS MANUAL PAGE 3 GLOSSARY AND SYMBOLS PAGE 4 RIGHT HAND AND LEFT HAND STANDARD PAGE 6 SAFETY PAGE 7 OBSERVATIONS PAGE 9 INDEX PAGE 9 OPERATIVE TEC...

Page 9: ...cial tools and other information See the symbols lists for their significance The procedures are described step after step PURPOSE OF THE MANUAL Principally this manual has been written for MV Agusta...

Page 10: ...of the relative cylinder In order to allow the motor to function under the best conditions it is necessary that all of the couplings are within the accepted toler ances established A tight coupling is...

Page 11: ...ecommended brake fluid Use the recommended suspension fluid Use the recommended coolant Use the recommended thread locking fluid Use the recommended sealant Use the recommended adhesive Carry out accu...

Page 12: ...y 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 Left side Right si...

Page 13: ...nment Keep used oil out of the reach of children Engine coolant Under certain situations the ethylene glycol contained in the engine coolant is inflammable and its flame is invisible Ethylene glycol w...

Page 14: ...ly nitrogen to pressurise the shock absorber The use of unstable gases can cause explosions that could cause burns Do not place the shock absorber near to flames or sources of heat as this could cause...

Page 15: ...em in con tainers respecting exactly the order of disassembly Always use the special utensils where necessary and each time where prescribed Always use adhesives sealants and lubricants where pre scri...

Page 16: ...ENTIFICATION 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 ZCG F5 11 B...

Page 17: ...1 B Maintenance SECTION B Revision 0...

Page 18: ...2 Maintenance B SUMMARY PLANNED MAINTENANCE SCHEDULE PAGE 3 ADJUSTMENT AND CALIBRATION OF THROTTLE BODY PAG 11...

Page 19: ...00 600 3800 7500 11200 14900 18600 22400 Pre delivery Description Procedure Motor oil Substitution At least every year Motor oil filter Each time engine oil is renewed Cooling liquid Check Top up Subs...

Page 20: ...sually check for damage At least every 6 months Side stand Check operation Side stand Check operation switch Rear wheel hub Check Substitution Big fork bearings Check lubrification Big fork chain shoe...

Page 21: ...O MA SAE 20 W 50 o 10 W 60 The above specifications are to be found alone or in combination with others on the lubricating oil container Motor oil SAE 10 W 60 API SJ ACEA A3 JASO MA NOTE 5 B Maintenan...

Page 22: ...haust valve spring Internal External Inlet valve spring Internal External Valve cam clearance Exhaust Inlet STANDARD 24 6 mm 28 6 mm 1 mm 0 02 0 04 mm 0 01 0 03 mm 4 5 mm 4 475 0 005 mm 4 485 0 005 mm...

Page 23: ...scraper Maximum segment cylinder play 1 2 Scraper FRIZIONE Disk thickness Springs STANDARD 0 038 0 067 mm 0 004 0 012 mm 0 015 0 032 mm 0 8 mm 0 8 mm 1 5 mm 0 2 0 4 mm 0 2 0 4 mm 0 2 0 7 mm 3 mm 41 m...

Page 24: ...lection gear limit Primary 5a 6a Secondary 1a 2a 3a 4a Fork pit play BEDPLATE DRIVE SHAFT Bed bearing functioning play Connecting rod bearing Functioning play Drive shaft axial play STANDARD 0 35 0 15...

Page 25: ...ning rings in deformable material and self blocking nuts must always be substituted The bearings are dimensioned for a determined num ber of working hours Substitution is therefore recom mended in con...

Page 26: ...value of the reported range check the following points A carbon deposits on the walls of the combustion chamber and on the piston ceiling B lthe head gasket is not of the correct measure ments N B If...

Page 27: ...da control Lambda range the Lambda mvolt will range between a high of 1000 mvolt and a low of 0 mvolt minus the diagnostic soft ware lag To see the range more clearly adjust the two graphic settings T...

Page 28: ...them 1 5 turns off the all closed position For this adjustment it is compulsory to begin with cylin der 2 to make sure the EBS valve will work properly Cylinder 2 provides the following positions min...

Page 29: ...rk within a range of 4 to 4 When the adjustment is over turn off the vehicle remove the connection pipe and replace the four pro tective plugs Not required adjustment of carbon oxide rate CO CO ADJUST...

Page 30: ...14 Maintenance B...

Page 31: ...1 C Cylinder kit SECTION C Revision 0...

Page 32: ...2 Cylinder kit C SUMMARY CYLINDER HEAD PAGE 3 DISTRIBUTION CONTROL UNITS PAGE 7 CYLINDER AND PISTON UNIT PAGE 27...

Page 33: ...apply neither oil nor other types of substances GR Apply grease SS Apply silicone sealing HSC Apply HSC Molikote M Apply mastic for gaskets CYLINDER HEAD A B C D E F G H I L N m 12 10 50 8 36 Tighten...

Page 34: ...ve cover 2 proceed carefully so as not to damage the gasket 3 When refitting it is essential to apply silico ne sealant as shown in the figure at the beginning of the chapter On the left side of the m...

Page 35: ...otate the drive shaft up to the point where the n 1 piston is at MSP in burst phase In this position the T notch on the phonic wheel is lined up with the reference notch on the bedplate The cams relat...

Page 36: ...ve the chain tensioner by means of the two tightening screws First remove the 2 external stands 4 and 5 of the camshafts by means of the four screws each internally hexagonal At the same time remove t...

Page 37: ...TION CONTROL UNITS OIL Apply motor oil NO OIL Do not apply neither oil nor other types of substances GR Apply grease SS Apply silicone sealing HSC Apply HSC Molikote M Apply mastic for gaskets Tighten...

Page 38: ...istribution chain First remove the unloaded end of the gearshaft Fasten the distribution chain with copper thread in order to retrieve it during the following procedure Remove the inlet end of the cam...

Page 39: ...the head begin ning from the external ones proceeding towards the internal ones following the sequence indicated in the figure On each encarcement there is a washer Be carefully no to let it fall int...

Page 40: ...ction of the head group Remove carbon deposits from the combustion cham bers Clean away eventual encrustments from the canalizations of the cooling liquid Check to be sure that are no crack and that t...

Page 41: ...cylinder plane distance with the n 8000A3406 tool tightening the head nuts at 32 N m The choice is made following table below The cylinder base gaskets always have the same thickness see table Distanc...

Page 42: ...e of the HSC MOLI KOTE type only on the nut threads Do not apply grease on the encarcement threads which must be well cleaned and degreased Screw the bolts with a brugle key and press them at 35 N m T...

Page 43: ...e in this position T notch on the phonic wheel is in line with the reference notch on the bedplate Remove the copper thread from distribution chain keep the chain tightened Engine timing is required w...

Page 44: ...14 Cylinder kit C Pin number 24 Pin number 25 Pin number 1...

Page 45: ...ith the engi ne installed on the vehicle lift the front wheel until the axis of the cylinders is in a vertical position Position the n 2 and n 3 stands referring to the num bers towards the inlet end...

Page 46: ...ually position the screws thus tighten at 8 Nm Place the adduction oil tube at the head greasing the O Rings Dismounting cylinder head pieces In order to carry out this procedure the following tools a...

Page 47: ...ively use tool n 95179 so as to avoid bending the valves C Assemble the head on tool n 800094796 D Hammer on the superior disk with a rubber hammer to unblock the semi cones E Press the springs on the...

Page 48: ...18 Cylinder kit C 800094798...

Page 49: ...oo thin or irregular it will be necessary to repair it Thickness of the stroke surface of the slot standard exhaust inlet 1 mm E The repair must be carried out by milling the slots using the appropria...

Page 50: ...considering that the assembling interference should be 0 10 0 15 mm C Valve slots are furnished with an increased replace ment part of 0 03 mm on the external diameter D Slowly and evenly heat the hea...

Page 51: ...ar between guide and valve stem it is necessary to measure the play using a control tampon and micrometer The control stopper 800095429 4 55 must not pass In the case of substituting the guide valve i...

Page 52: ...o be sure the valve slides freely in the valve guide otherwise coat it with a 4 5 H7 reamer or broach N 8000A2625 Valvola The stem diameters must not fall below 4 485 3 100 mm inlet 4 475 3 100 mm exh...

Page 53: ...not inferior to the suggested limit and in such case substi tute the springs Exhaust valve Internal spring L 33 8 mm Service limit 33 3 mm External spring L 37 9 mm Service limit 37 4 mm Inlet valves...

Page 54: ...re inserted D Using a rubber hammer strike a slight blow on the valve so as to place the semi cones Before placing the semi cones be sure that the head is not resting on a plane in order to avoid dist...

Page 55: ...ibuti on opening A Rotate the drive shaft until completely unwinding the springs relative to the valves on which intervening MSP in burst phase B Measure valve play with a thickometer C Calculate the...

Page 56: ...response Replace the assembly in case of malfunction If everything works properly lubricate the parts and install the assembly with the chain tensioner in the minimum extension position all in the mai...

Page 57: ...P OIL Apply motor oil NO OIL Do not apply neither oil nor other types of substances GR Apply grease SS Apply silicone sealing HSC Apply HSC Molikote M Apply mastic for gaskets A B C D E F G H I L N m...

Page 58: ...damage the elastic strips Work on one piston at a time to continue the removal First remove the 2 pistons which are at the MSP and rotate the drive shaft at 180 and disassemble the 2 remaining piston...

Page 59: ...ry also substitute the pistons and elastic strips The cylinder is marked with a letter which indicates the class it belongs to A and B cylinders and A and B pistons exist which must be coupled with th...

Page 60: ...rom the shell base in a perpendicular position to the piston pin axle These measurements must be carried out at a stabili zed temperature of 20 The play between piston and cylinder must fall bet ween...

Page 61: ...ecommen ded to change the pistons as well Segment cylinder coupling Introduce the 5 mm segment under the head plane being careful to position it well in square and to mea sure the distance between the...

Page 62: ...ny pieces from fal ling into the oil cup Always use new blocking rings Assemble a new gasket between the cylinder and bed plate Position the clamps onto the pistons in the direction shown in the sketc...

Page 63: ...1 D Crankcase SECTION D Revision 0...

Page 64: ...2 Crankcase D SUMMARY CLUTCH PAGE 3 GEAR AND GEAR CONTROL PAGE 12 WATER PUMP PAGE 19 STARTING PAGE 24 ENGINE BLOCK PAGE 26 COVERS PAGE 27 MAINSHAFT PAGE 37...

Page 65: ...S Apply silicone sealing HSC Apply HSC Molikote M Apply mastic for gaskets A B C D E F G H I L N m 8 140 10 4 5 Tightening torque Thread blockers Strong 1 code 8000A6917 q ty 2 2 code 8000A6916 q ty 7...

Page 66: ...he disk pusher plate function Clutch disassembly In order to carry out this function the following special tool is necessary Utensil n 800079015 Remove the 11 screws which fasten the clutch cap to the...

Page 67: ...be sure to refit it from the clutch control cylinder side right side of the engine with the lubrica tion groove facing the clutch Manually remove all of the attrition disks 3 that you can Unscrew the...

Page 68: ...6 Crankcase D Remove the spacer 6 and the grazer washer 7 Disassemble the clutch block following the sequence in the figure 6 7...

Page 69: ...3 mm Maximum allowed wear limit 2 8 mm No signs of burning grooves or other damages are allowed Replace the whole plates group even if only one is damaged Put the plate on a table and check the deform...

Page 70: ...er in front of the clutch drum is obtained by blanking it has a sharp edge and a rounded edge Fit the washer so that the rounded edge faces the engine Install the flange with the six columns already a...

Page 71: ...the diagram below First fit in one of the two disks 1 with the larger fric tion cells and a plain disk 3 Fit in the spring holder 5 the spring 6 with the nar rower diameter facing the engine and the...

Page 72: ...10 Crankcase D Fit in the dish pusher the six spring holders the plates the springs the self centring washers and the screws tighten the screws to the prescribed torque in a criss cross pattern...

Page 73: ...11 D Crankcase Finally take a gauge and check if the measured dis tance between the outer surface of the disk pusher and the packed disk is consistently 5 0 1 mm in the four holes...

Page 74: ...il NO OIL Do not apply neither oil nor other types of substances GR Apply grease SS Apply silicone sealing HSC Apply HSC Molikote M Apply mastic for gaskets A B C D E F G H I L N m 140 8 8 6 25 M8 25...

Page 75: ...from the gear cap Using a rubber hammer delicately beat on the primary shaft from the clutch end holding a hand on the gear cap until it moves from the bedplate Slide the gear group out To avoid damag...

Page 76: ...it 0 65 mm Groove width of a new drum 7 05 7 15 mm Wear limit 7 35 mm The new fork pin diameter is equal to 6 8 6 9 mm Wear limit 6 7 mm Verify the working clearance between the fork pin and the shift...

Page 77: ...nkcase Primary and secondary shaft Check the two shafts separate ly so as to avoid confusion of similar components Place the components in such a way as to facilitate the correct positioning dur ing r...

Page 78: ...inside of the gear box Verify the control quotas indicated on the sketch in the figure Gear selection forks Visually inspect the gear selection forks to look for folds or other damage Every fork that...

Page 79: ...he 2 shafts on the n 8A0094792 engine simulation tool Install a shift pedal and check the gear box is correctly working Always install a new washer under the pinion at reassem bly Carefully degrease t...

Page 80: ...each gear ing once inserted presents a fork pit play equal to 0 2 0 3 mm placing it on both ends of the coupling The fork must be free Assemble the gasket on the internal end Before inserting the gea...

Page 81: ...ly motor oil NO OIL Do not apply neither oil nor other types of substances GR Apply grease SS Apply silicone sealing HSC Apply HSC Molikote M Apply mastic for gaskets A B C D E F G H I L N m 8 Tighten...

Page 82: ...t of the bedplate Scomposizione organi pompa acqua After having extracted the pump from the bedplate disassemble the pump as follows A Remove the tightening screws from the pump body 1 and separate th...

Page 83: ...es Verify that each component does not show any wear signs In particular verify the flowness of the bearings and the O Ring condition Verify that the impeller does not show signs of giving away or sli...

Page 84: ...Always fit new rings after carefully degreasing them with alcohol C Fit the first bearing 7 D Fit the tip on shaft 5 and then insert the shaft into its housing E Fit the second bearing 6 F Lock the a...

Page 85: ...y A Insert the pump on the bedplate being very careful not to damage the O Ring on the pump body B Insert the screws 1 which fix the pump body onto the bedplate C Install the coupling with its clamp o...

Page 86: ...l NO OIL Do not apply neither oil nor other types of substances GR Apply grease SS Apply silicone sealing HSC Apply HSC Molikote M Apply mastic for gaskets A B C D E F G H I L N m 10 55 25 Tightening...

Page 87: ...ere the seeger is opened last Verify that the free wheel only turns clockwise Assemble the group on the tool 800094795 and block the screw with a dynamometric key at 25 N m and MEDIUM THREAD BLOCKER R...

Page 88: ...10 60 22 8 14 25 30 Tightening torque Thread blockers Medium Medium Medium Medium OIL Apply motor oil NO OIL Do not apply neither oil nor other types of substances GR Apply grease SS Apply silicone se...

Page 89: ...l NO OIL Do not apply neither oil nor other types of substances GR Apply grease SS Apply silicone sealing HSC Apply HSC Molikote M Apply mastic for gaskets A B C D E F G H I L N m 10 25 10 8 35 Tighte...

Page 90: ...o cracks or slits clean it with compressed air at a low pressure blown from the inside towards the outside To remove the oil inlet filter unscrew the tightening screws At reassembling tighten the 2 sc...

Page 91: ...d B The cylinder group C The pistons D The clutch E The gear Remove F The size 6 screws including the one for the blow by cap Remember to unscrew the screw inside the carter indicated in the picture a...

Page 92: ...with a number using a marker For example the bushing removed from the n 1 bearing of the superior carter starting from the left will be identified by the mark S1 For the couplings refer to the groups...

Page 93: ...r tolerance The function play of the bench bearings must be between 0 012 0 038 mm Service limit is 0 06 mm The function play of the connecting rod bearing must be between 0 036 0 061 mm With a servic...

Page 94: ...ate the nr 5 support as it carries out the function of the motor shaft centering Put the new cap on the right side after having put the silicone type paste on the cap s surface between cap and carter...

Page 95: ...r Reassemble the bearing on the inferior semi carter with the locks facing each other and turned inward the bedplate Be sure that the centering bushes are installed on the inferior semi carter Spread...

Page 96: ...screws manually manipulating them and tighten them to the coupling at 10 N m Tighten all the screws inversely to the order they were disassembled Install the heat exchanger with the O Ring and lock th...

Page 97: ...The measurement has to be carried out on the princi pal axle of the stem after having tightened at 35 N m If substitution of one or more parts is necessary it is sufficient to follow the indications o...

Page 98: ...plate as shown in the following picture Attention the drive shaft in this position is NOT in the MSP position Fit the distribution chain on the intermediate gear Position the intermediate gear being c...

Page 99: ...K N m 25 Tightening torque Thread blockers Medium OIL Apply motor oil NO OIL Do not apply neither oil nor other types of substances GR Apply grease SS Apply silicone sealing HSC Apply HSC Molikote M...

Page 100: ...38 Crankcase D...

Page 101: ...1 E Lubrication SECTION E Revision 0...

Page 102: ...2 Lubrication E SUMMARY OIL PUMP PAGE 3 SUBSTITUTE OL FILTER PAGE 5...

Page 103: ...ly motor oil NO OIL Do not apply neither oil nor other types of substances GR Apply grease SS Apply silicone sealing HSC Apply HSC Molikote M Apply mastic for gaskets A B C D E F G H I L N m 8 Tighten...

Page 104: ...e clutch end To disassemble the oil pump remove the external screws Separate the various components as indicated in the figure Visually check the components to be sure that there are no lines of defor...

Page 105: ...e Tighten the filter using the appropriate tool code 99010 and a dynamometric key Tightening couple 24 N m Once the filter has been tightened Take the new motor oil filter clamp and the relative screw...

Page 106: ...nsure that the dis tance between the screw and the clamp fastener is 1 to 1 5 mm see figure Run the engine for 3 minutes and then check that no oil is leaking from the filter WARNING Do not use the oi...

Page 107: ...1 F Electrical components SECTION F Revision 0...

Page 108: ...2 Electrical components F SUMMARY ELECTRICAL COMPONENTS PAGE 3...

Page 109: ...y motor oil NO OIL Do not apply neither oil nor other types of substances GR Apply grease SS Apply silicone sealing HSC Apply HSC Molikote M Apply mastic for gaskets A B C D E F G H I L N m 10 25 10 2...

Page 110: ...the rubber torsions fall Assembly Grease the torsions and O Rings Insert the pallets together with the torsions Manually bring the screws together thus tighten them at 25 Nm Starter motor Removal Remo...

Page 111: ...1 G Tightening torques SECTION G Revision 0...

Page 112: ...2 Tightening torques G SUMMARY TIGHTENING TORQUES PAGE 3...

Page 113: ...crews 25 medium M6 gear control screws 8 medium ENGINE ACCESSORIES Alternator tightening screws 25 Motor starter tightening screws 10 Water pump tightening screws 8 Neutral switch screws 10 FREE WHEEL...

Page 114: ...ESCRIPTION N m Thread blockers CRANKCASE Clutch cap M6 screws 8 M6 bearing clamp screw 12 medium M6 screws 10 M8 x 95mm torque screws 10 60 M8 torque screws 25 Bearing exchange screws 10 Exchanger scr...

Page 115: ...H Service tools SECTION REVISION 0 H 1...

Page 116: ...H Service tools 2...

Page 117: ...800051521 2 SCREW M4X6 16 800095429 1 CONTROLPAD 17 800095581 1 VALVE SEAL ASSEMBLY TOOL JOINTS 18 8000A2385 1 GUIDE ASSEMBLYPAD 19 800097867 1 ENGINE MOUNTING 20 800095179 1 HALF CONES DISASSEMBLYTOO...

Page 118: ...H Service tools 4...

Page 119: ...1078 DESCRIPTION Service tools 5 1 8000A2281 1 TIMING CHAIN CUTTING TOOL 2 8000A2280 1 TIMING CHAIN MOUNTING TOOL 3 800079015 1 CLUTCH BLOCKING TOOL 4 800095318 1 PAD FOR EXHAUST VALVE SEAT 5 80009531...

Page 120: ...H Service tools 6...

Page 121: ...I Analytical index SECTION REVISION 0 I...

Page 122: ...enance schedule B 3 Sez C Cylinderkit Chain tensioner C 26 Cylinder head C 3 Cylinder and pistons unit C 27 Distribution control unit C 7 Phase sensor C 8 Sez D Crankcase Mainshaft D 37 Starting D 24...

Page 123: ......

Page 124: ...STA S p A Servizio Assistenza Tecnica Via Giovanni Macchi 144 21100 Varese VA ITALY Tel Italia 800 36 44 06 estero 39 0332 254 712 Fax 39 0332 329 379 sito web www mvagusta it Part N 8A00B2576 Edizion...

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MV Agusta 2008 F4 312RR 1078, Workshop Manual

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