MV Agusta F4 1000 S Workshop Manual Download

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ANALYTICAL INDEX - F4 1000 WORKSHOP MANUAL

Section A - General Description

Glossary and symbols . . . . . . . . . . . . . . . . . . .A-4

How to consult the manual . . . . . . . . . . . . . . . .A-3

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8

Operative technical specification . . . . . . . . . . .A-9

Purpose of the manual . . . . . . . . . . . . . . . . . . .A-3

Right hand and left hand standards . . . . . . . . .A-5

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6

Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8

Section B - Maintenance

Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-40

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-60

Brake pads . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-71

Brakes and clutch . . . . . . . . . . . . . . . . . . . . . . .B-44

Electric cooling fans . . . . . . . . . . . . . . . . . . . . .B-14

Electrical system . . . . . . . . . . . . . . . . . . . . . . .B-60

Engine coolant . . . . . . . . . . . . . . . . . . . . . . . . .B-11

Engine oil and oil filter . . . . . . . . . . . . . . . . . . .B-8

Front forks . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-60

Front headlight . . . . . . . . . . . . . . . . . . . . . . . . .B-90

Front wheel bearings . . . . . . . . . . . . . . . . . . . .B-56

Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-27

Fuel pump assembly . . . . . . . . . . . . . . . . . . . .B-33

Fuel union tubes . . . . . . . . . . . . . . . . . . . . . . . .B-36

Fuel tubes assembly . . . . . . . . . . . . . . . . . . . .B-36

Instruments and warning lights . . . . . . . . . . . .B-61

Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-82

Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-51

Maintenance and tuning operations . . . . . . . . .B-8

Periodical maintenance schedule . . . . . . . . . .B-6

Rear shock absorber . . . . . . . . . . . . . . . . . . . .B-58

Rear wheel hub . . . . . . . . . . . . . . . . . . . . . . . .B-57

Screw and nuts . . . . . . . . . . . . . . . . . . . . . . . .B-60

Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-59

Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . .B-25

Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-53

Swingarm bearings . . . . . . . . . . . . . . . . . . . . .B-57

Technical information . . . . . . . . . . . . . . . . . . . .B-3

Throttle control . . . . . . . . . . . . . . . . . . . . . . . . .B-49

Throttles body adjustament and tuning . . . . . . . .B-51

Transmission chain . . . . . . . . . . . . . . . . . . . . .B-53

Tube band fasteners . . . . . . . . . . . . . . . . . . . .B-60

Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-56

Valve mechanism adjustment . . . . . . . . . . . . .B-15

Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-75

Section C - Bodywork

Air intake system . . . . . . . . . . . . . . . . . . . . . . .C-20

Fairing assembly . . . . . . . . . . . . . . . . . . . . . . .C-3

Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-12

Heat shield . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-25

Mudguard - Central spoiler -

Radiator protection . . . . . . . . . . . . . . . . . . . . . .C-25

Tail unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-6

Section D - Air intake injection system

Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-13

Air intake system technical characteristics . . .D-15

Diagnostic system . . . . . . . . . . . . . . . . . . . . . .D-14

ECU (Electronic control unit) . . . . . . . . . . . . . .D-9

Engine-control system - Position of the parts . .D-17

Fuel feed system . . . . . . . . . . . . . . . . . . . . . . .D-5

Fuel injector . . . . . . . . . . . . . . . . . . . . . . . . . . .D-6

Fuel pressure regulator . . . . . . . . . . . . . . . . . .D-6

Fuel pump check . . . . . . . . . . . . . . . . . . . . . . .D-11

Fuel pump control system . . . . . . . . . . . . . . . .D-7

Injection arrest control . . . . . . . . . . . . . . . . . . .D-4

Injector check . . . . . . . . . . . . . . . . . . . . . . . . . .D-11

Injection system technical characteristics . . . .D-3

Injection system electrical diagram . . . . . . . . .D-18

Injection time compensation (Volume) . . . . . . .D-4

Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-8

– Atmospheric air temperature/pressure . .D-8
– Throttle body position . . . . . . . . . . . . . . .D-10

Technical specifications -

secondary air system . . . . . . . . . . . . . . . . . . .D-16

Section E - Electrical system

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-7

– Battery assembly . . . . . . . . . . . . . . . . . . .E-8

– Efficiency check . . . . . . . . . . . . . . . . . . . .E-13

– Initial charge . . . . . . . . . . . . . . . . . . . . . . .E-11

– Recharging system . . . . . . . . . . . . . . . . .E-7

Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3

- 2 -

Analytical index

Summary of Contents for F4 1000 S

Page 1: ......

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: ...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: ...K AIR INTAKE INJECTION SYSTEM ELECTRICAL SYSTEM SUSPENSION AND WHEELS FRAME BRAKES COOLING SYSTEM SPECIAL TOOLS TORQUE PRESSURES DIAGNOSTICS ANALYTICAL INDEX Rev 0 B Rev 1 C Rev 0 D Rev 1 E Rev 1 F Re...

Page 6: ......

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

Page 8: ...ARY 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 5 SAFETY PAGE 6 OBSERVATIONS PAGE 8 INDEX PAGE 8 OPERATIVE TE...

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: ...t of the operation NOTE Utilise a specific tool or equipment for the correct carrying out of the operation described Tighten to the specified torque Tolerance or limit of use Utilise the tester Use th...

Page 11: ...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 A Right side Left si...

Page 12: ...the environment 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 Ethylen...

Page 13: ...urise 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 explosions with con...

Page 14: ...hem 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 scr...

Page 15: ...side of the steering head The engine registration number is stamped on the upper engine casing near the forks ZCG F6 10 AA Y V 000000 Manufacturer identification Vehicle model Progressive frame numbe...

Page 16: ...10 General description A...

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

Page 18: ...TLE BODY ADJUSTMENT AND CALIBRATION PAGE 37 BRAKES AND CLUTCH PAGE 44 BRAKE CLUTCH GEARCHANGE COMMANDS CHECK PAGE 47 BRAKE PADS PAGE 49 THROTTLE CONTROL PAGE 49 LOCKS PAGE 51 STEERING PAGE 53 TRANSMIS...

Page 19: ...ription F4 1000 CHARACTERISTICS Wheelbase mm 1430 Total length mm 2100 Maximum width mm 750 Seat height mm 830 Ground clearance mm 115 Trail mm 100 4 Dry weight kg 192 Fuel tank capacity lt 17 Fuel re...

Page 20: ...mesh gears Gear ratios total ratios 1st 2 64 11 39 2nd 2 06 8 88 3rd 1 72 7 42 4th 1 50 6 47 5th 1 32 5 69 6th 1 19 5 13 FRAME Type CrMo steel tubular trellis TIG welded Fork fulcrum plates Aluminium...

Page 21: ...2 in 1 in 2 in 4 ELECTRICAL SYSTEM System voltage 12V Headlight bulb PHILIPS XenStart D1S 35W Tail light bulb 12V 5W Battery 12V 8 6Ah Alternator 350 W at 5000 r p m HEADLIGHT Type Centrally mounted...

Page 22: ...er G G G G G G G At every substitution of engine oil Engine coolant Check level and top up G G G G G G G G Substitution At least every two years Cooling system Check for leakages G G G G G G G G Elect...

Page 23: ...heck functioning G G G G G G G G Side Check functioning G G G G G G G G stand switch Rear wheel hub Check G G Substitution G Swingarm bearings Check lubricate G Drive chain pads on swingarm Check subs...

Page 24: ...ed tool see figure remove filler plug 1 on the right side of the vehicle so as to facilitate the outflow of the oil 8 Maintenance B NOTE Description Recommended product Specifications Engine oil AGIP...

Page 25: ...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 2 Substitution of the oil filter Re...

Page 26: ...lean Replace the sealing washer with a new one Screw in the oil discharge plug and tighten it to the specified torque Torque pressure oil discharge plug 35 N m Pour around 3 kg of engine oil as specif...

Page 27: ...ence notch correct it by emp tying a little oil out of the engine Oil pipes During ordinary maintenance operations ensure that the different components are properly fitted and that no oil is leaking f...

Page 28: ...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 If t...

Page 29: ...d the condition of the gasket Torque pressure engine coolant discharge plug 8 10 N m Lift the front part of the motorcycle as shown in the figure Fill the cooling system with a suitable liquid describ...

Page 30: ...TRIC COOLING FANS Check on pre delivery and at the first 1000 kilometres and then every 6000 kilome tres To carry out the check on the functioning of the electric cooling fans switch on the engine and...

Page 31: ...otes please refer to the specific sec tions in this manual An analogous reference is utilised for the reassembly of the parts after the maintenance operation After having removed the indicated compone...

Page 32: ...p 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 16 Maintenance B Maintenance Systemi...

Page 33: ...B Remove the plastic covers 1 and remove the 8 fixing screws of the cover of the engine head 2 Lift the front part of the motorcycle as shown in the figure 1 2 Remove the wiring clamps on the right si...

Page 34: ...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 Disconnect the...

Page 35: ...oval 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...

Page 36: ...g of the engine by ensuring that the inci sion stamped on tooth A of the timing wheel is in line with the tooth B that is present on the engine casing The following photograph illustrates clearly the...

Page 37: ...substituting the valve cups CYLINDER 1 CYLINDER 2 CYLINDER 3 CYLINDER 4 INTAKE Valve n 1 Valve n 2 Valve n 3 Valve n 4 Valve n 5 Valve n 6 Valve n 7 Valve n 8 Valve play Pad thickness CYLINDER 1 CYLIN...

Page 38: ...e 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 These must anyway also be written in the table previ ously...

Page 39: ...ed 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 exhaust valves n 9 10 13 14 Make a n...

Page 40: ...e substitute the camshaft valve cup play adjustment pads as described in the F4 1000 workshop engine manual F4 1000 Code 8000B4302 If the values are correct reassemble in reverse order to disassembly...

Page 41: ...d 8000B4302 SPARK PLUGS Check substitute At 6000 kilometres and then every 12000 kilometres Substitute Every 12000 kilometres The following components must be removed to accede to the spark plugs Unde...

Page 42: ...ely used or burnt substitute the spark plugs Also substitute the spark plugs in the case of breakage of the ceramic isolation or damage to threading When the spark plugs are renewed check the thread p...

Page 43: ...passenger seat Rear side panels Fuel tank NOTE Consult chapter C Bodywork Carry out the following operation Fuel filler cap removal Insert the ignition key in the fuel filler cap lock and rotate in a...

Page 44: ...assembly removal Turn the tank upside down and remove the eight screws for fixing the flange to the tank 1 1 Lift up the flange 1 and disconnect the tubes 2 on both sides of the flange Remove the two...

Page 45: ...el 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 We recomm...

Page 46: ...e cable clamp must be cut Disconnect the connector of the thermistor cabling During re assembly if the O Rings have been repla ced lubricate surface lightly with silicone grease The use of worn O Ring...

Page 47: ...s to be replaced it is first necessary to remove the lower clamp and take the tube out of the cartridge Remove the upper clamp in the same way and take out the tube Take the thermistor out of its hous...

Page 48: ...ert 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...

Page 49: ...Maintenance 33 B Maintenance FUEL PUMP ASSEMBLY...

Page 50: ...g 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 su...

Page 51: ...opriate spigot on the die cast flange Tighten the band fasteners by using the CLIC 205 pincers Specific pliers CLIC R 205 Part code 800095850 1 2 1 2 Gently press down the flange assembly into its sea...

Page 52: ...nd FUEL TUBE ASSEMBLY Substitute At least every three years The procedure to follow in the case of substitution of the feed tubing is as follows Remove in this order Fairing side panels Under engine f...

Page 53: ...conds to enable the control unit to store new resets Then connect the vacuum gauge and the engine will start warming up You will see that after starting the engine the Lambda channel mvolt which was n...

Page 54: ...ese instructions check that all by pass adjustment screws 1 of the 4 cylinders are pre positioned at an opening of 1 5 turns from the fully closed position choose the cylinder corresponding to the hig...

Page 55: ...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 igni...

Page 56: ...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 Rear le...

Page 57: ...ck Make sure that the cover is fastened properly by awai ting the click of the five tabs Unhook the two front clips 3 and remove the cover 4 Remove the filter 5 Check the condition of the air filter I...

Page 58: ...42 Maintenance B 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...

Page 59: ...d below and according to the procedure described in chapter C Bodywork Fuel tank Left side panel Airbox Right side panel Airbox Rear left side panel Rear right side panel Left side panel tank Right si...

Page 60: ...heck the fluid levels in the brake and clutch fluid chambers observing the lines for the level marked on the chambers If the level of the fluid is lower than the lines marked on the chambers add recom...

Page 61: ...fect cleaning of these parts could cause the discharge of small quantities of brake fluid during riding Brake fluid has strong corrosive properties Check eventual leaks and blow bys of brake and clutc...

Page 62: ...e 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 remove the 2 screws from the reser...

Page 63: ...brat ed to a standard position but can be altered as follows Front brake and clutch lever adjustment Never carry out adjustments whilst riding the motorcycle Pull the lever to neutralise the push of t...

Page 64: ...ken 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 Tighten the screw 1 to the torque prescribe...

Page 65: ...raking efficiency THROTTLE CONTROL Throttle control play check At the pre delivery check at the first 1000 kilome tres and then every 6000 kilometres The throttle control should not be too tight or to...

Page 66: ...ecessary to consult chapter D Air intake injection system 50 Maintenance B Maintenance After making adjustments check that the throttle valves open slightly by activating the choke lever 1 as indicate...

Page 67: ...key cannot be pulled out Do not attempt to change the functions of the ignition switch whilst the motorcycle is being ridden It could cause the rider to lose control of the machine LOCK position Turn...

Page 68: ...u must perform the following operations Rotate the key into the lock Press down the passenger seat Release the key Press down the seat once more so to make sure of its firm coupling to the frame If th...

Page 69: ...wer portion must be 50 mm from the lower chain guard Manually turn the rear wheel and perform the check at different points along the chain As the wheel is turned the play should remain virtual ly the...

Page 70: ...figure move the eccentric adjuster nut backwards or forwards respectively slackening or tightening the chain until the correct play is reached as described previously Maintenance 28 32 N m Successive...

Page 71: ...y 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 s...

Page 72: ...then substitute them as indicated in chapter F Suspension and wheels Maintenance 1 5 mm TYRES Check pressures At the pre delivery at the first 1000 kilometres and then every 6000 kilometres Check wea...

Page 73: ...ary to carry out certain preliminary operations by consulting the relative chapters Remove the rear wheel see chapter F Suspension and wheels Lift up the motorcycle by utilising a mechanic s lift Remo...

Page 74: ...170 5 mm The shock absorber contains gas under high pressure Do not touch the shock absorber valve Do not attempt in any way to remove the shock absorber Extension and compression adjustments rear su...

Page 75: ...en the two screws to the prescribed torque Torque pressure 5 7 N m Apply Loctite Media 243 Reconnect the electrical connector Check that the side stand is not worn To remove the stand follow these ste...

Page 76: ...apter N Torque pressures for the correct values TUBE BAND FASTENERS Check and tighten At the pre delivery at the first 1000 kilometres and then every 6000 kilometres Carry out a general check on all t...

Page 77: ...ghts blue It turns on when the headlights are on 4 Battery charge indicator red Lights up when the alternator does not supply enou gh current to charge the battery If the indicator comes on while ridi...

Page 78: ...though the level is correct not continue to run and contact an authorised service cen tre 11 Gear display It displays the currently engaged gear N stands for neutral 12 Speedometer It displays the spe...

Page 79: ...LIZER function Anti theft system Control unit mapping selection Selecting the display functions The following settings may be changed on the display RUN Odometer TC Traction control CHRONO Chronometer...

Page 80: ...l odometer TOTAL Trip counter 2 TRIP 2 TC Mode This Mode adjusts the engine traction control level to your driving requirements CHRONO Mode This mode turns on the Chronometer and saves the recorded in...

Page 81: ...eset TRIP 1 and TRIP 2 proceed as follows WARNING The display modes may be changed or set when the engine off the gear in neutral the motorbike stationary with your feet on the ground The display may...

Page 82: ...will be reset to zero TC Mode Press the SET button to switch on TC mode then press the OK button for less than four seconds until the message TC LEVEL appears The current trac tion control level is th...

Page 83: ...seconds to confirm the selec ted traction control level Chronometer Lap timing acquisition Turn on the chronometer CHRONO mode to record the time taken to cover a lap Press the headlight button to sta...

Page 84: ...cords a time The instrument can record up to100 consecutive times When the time for the lap which has just concluded is displayed the symbol or appears if the time recorded is respectively higher or l...

Page 85: ...epeatedly 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...

Page 86: ...the display while dri ving Cancellation of individual time recordings Access the CHRONO mode and press the SET key for less than four seconds until the words SINGLE LAP RESET appear on the display Pr...

Page 87: ...all the data have been cancelled press the SET key to return to the SINGLE LAP RESET mode and then to the following mode Cancellation of best time Access the CHRONO mode and press the SET key for less...

Page 88: ...elled press the SET key to exit the BEST LAP RESET mode and then pass to the following mode Cancellation of all times recorded Access the CHRONO mode and press the SET key for less than four seconds u...

Page 89: ...DAY MODE and press the OK key for less than four seconds WARNING The display modes may be changed or set when the engine off the gear in neutral the motorbike stationary with your feet on the ground...

Page 90: ...printed on the MV Code Card received upon delivery of the vehicle to obtain engine start up consent Remove the lid from the box on the back of the MV Code Card and read the secret electronic code of...

Page 91: ...s OK for over four seconds to confirm the code If the entered code is recognised by the system VALID CODE appears The dashboard display goes back to RUN The engine may be started If the entered code i...

Page 92: ...WARNING Control unit mapping selection operations must be carried out with the engine running on neutral with the motorcycle stopped with the stand on the ground Changing display settings while runni...

Page 93: ...ce centre Vehicle running When a vehicle fault is detected while running an error message shown to the side is shown on the lower part of the display WARNING Whenever a fault is detected while the veh...

Page 94: ...ough the level is correct do not con tinue to run and contact an authorised ser vice centre Dealer Menu The instrumentation provides the opportunity to opera te on an additional set of parameters The...

Page 95: ...the motorcycle UNIT CHANGE Mode This function allows for simultaneous editing of the fol lowing units of measure Speed Distance covered SERVICE Mode Press the SET and OK buttons at the same time for...

Page 96: ...using the following procedure Access SERVICE mode and press the OK button for less than four seconds until the message RESET KM appears and the mileage range indicator light will begin to flash Press...

Page 97: ...ed Access the SERVICE mode as described in the pre ceding pages and press the SET button for less than four seconds to until the message UNIT CHAN GE appears Press the OK button for less than four sec...

Page 98: ...t 1000 kilometres and then every 6000 kilo metres If any of the warning lights or the main lights are burnt out replace them as follows Driving dipped beam Bulb replacement NOTE To facilitate operatio...

Page 99: ...Maintenance 83 B Turn the holding device counter clockwise Remove the bulb Disconnect the connector...

Page 100: ...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 Replace the cover NOTE In the event that the headlight i...

Page 101: ...Maintenance 85 B Maintenance Replacing the license plate light bulb Remove the fixing screws of the lower cover of the license plate holder Remove the lower cover...

Page 102: ...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 li...

Page 103: ...tion before checking or replacing the fuses in order to avoid a short circuit with subse quent damage to other electric parts of the motorcycle To replace the fuse you must swap the recharge fuse with...

Page 104: ...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 subs...

Page 105: ...osed 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 WARNING Never replace a fuse with a rating o...

Page 106: ...torcycle 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 th...

Page 107: ...1 Bodywork C SECTION C Revision 0...

Page 108: ...2 Bodywork C SUMMARY FAIRING ASSEMBLY PAGE 3 TAIL UNIT PAGE 6 FUEL TANK PAGE 12 AIR INTAKE SYSTEM PAGE 20 HEAT SHIELD PAGE 25 MUDGUARD CENTRAL SPOILER RADIATOR PROTECTION PAGE 28...

Page 109: ...C Bodywork This exploded view demonstrates the position of the bodywork and the method of disassembly and assembly 3 FAIRING ASSEMBLY Right side Left side...

Page 110: ...ixing 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 manifol...

Page 111: ...k 5 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 bra...

Page 112: ...r 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...

Page 113: ...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 The...

Page 114: ...8 Bodywork C TAIL UNIT...

Page 115: ...on 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 lev...

Page 116: ...k C 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 scre...

Page 117: ...C Bodywork 11 Remove the side fairing toward the outside taking care of the rear pin anchored in the support brackets...

Page 118: ...12 Bodywork C FUEL TANK...

Page 119: ...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 13 C Remove the vent tube Fuel tank remo...

Page 120: ...odywork C 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 airb...

Page 121: ...at 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...

Page 122: ...ct 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...

Page 123: ...e 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...

Page 124: ...able 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...

Page 125: ...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 integrit...

Page 126: ...AIR INTAKE SYSTEM 20 Bodywork C...

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 C...

Page 128: ...rews 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...

Page 129: ...Bodywork 23 C Unhook the oil vapour tube Lift the air box from its rear part removing the rubber tube Disconnect the upper injector cable connector 1...

Page 130: ...24 Bodywork C Lift and remove the airbox With the appropriate gripper loosen the secondary valve tube clip and remove the tube Remove the cable...

Page 131: ...HEAT SHIELD Bodywork 25 C...

Page 132: ...fter 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...

Page 133: ...Bodywork 27 C Remove the 6 fixing screws of the heat guard Lower and remove the guard toward the rear part Remove the headlight support...

Page 134: ...28 Bodywork C MUDGUARD CENTRAL SPOILER RADIATOR PROTECTION Right side Left side...

Page 135: ...ssembly 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 mu...

Page 136: ...move 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...

Page 137: ...Air intake injection system 1 D SECTION D Revision 1...

Page 138: ...E 8 SENSORS PAGE 8 ATMOSPHERIC AIR TEMPERATURE PRESSURE SENSOR PAGE 8 THROTTLE BODY POSITION SENSOR PAGE 10 INJECTOR CONTROL PAGE 11 FUEL PUMP CONTROL PAGE 11 ACTUATORS PAGE 13 DIAGNOSTICS SYSTEM PAGE...

Page 139: ...ccelerator 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 3 D Camshaft position senso...

Page 140: ...rature of the engine coolant is low the injection time volume is increased AIR INTAKE TEMPERATURE SENSOR SIGNAL When the temperature of the intake air is low the injection time volume is increased BAT...

Page 141: ...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 The fuel is injected into the air intake c...

Page 142: ...he fuel injects the fuel in a conical dispersion Given that the opening of the needle valve is constant the volume of fuel injected at any one time is dependent on the time that the solenoid is agitat...

Page 143: ...n switch has been brought to the ON position If the starter motor turns the electric motor shaft during or after the three sec onds the motor rotation signal is sent to the CPU that by controlling the...

Page 144: ...ion air sensor 1 is situated on the right suc tion duct in the front part of the vehicle and indicates both the atmospheric pressure and the air temperatu re 1 INTAKE AIR PRESSURE SENSOR The sensor 2...

Page 145: ...t 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 hi...

Page 146: ...r The sensor is supplied by the ECU at a stabilised vol tage of 5V and supplies an output voltage proportiona te to the throttle angle The basic injection time of the fuel volume is deter mined accord...

Page 147: ...d with the check of the coils of each injector Between the two pins of the injector the contact must not be open Also the resistance value must be between 12 0 12 3 If otherwise proceed by substitutin...

Page 148: ...in 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...

Page 149: ...the piston At the same time the needle valve incorporated in the piston opens and the injector under pressure of the fuel injects the fuel in a conical dispersion Given that the opening of the needle...

Page 150: ...ich 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...

Page 151: ...n 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 improvin...

Page 152: ...gh 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 So when needed the system prom...

Page 153: ...ant temperature sensor C Ignition coils D Camshaft position sensor E Intake air pressure temperature sensor F Fuel pump G Accelerator position sensor H Fuel injectors I Fuses relays L Engine control u...

Page 154: ...CLUTCH SWITCH SIDE STAND SWITCH NEUTRAL SWITCH TILT SENSOR PICK UP WHEEL FULE PUMP INJECTOR FUSE COIL ECU FUSE PRESSURE SENSOR UNDER THROTTLE THROTTLE BODY LOWER INJECTRS THROTTLE BODY UPPER INJECTRS...

Page 155: ...high injectors OFA LOW SIDE 46 PHASEIN Input engine HALL phase sensor IFA PULL UP 47 TPS1 Throttle body throttle position input TPS IA PULL UP RATIO 48 TPSRED1 Exhaust valve throttle position input I...

Page 156: ...20 Air intake injection system D...

Page 157: ...Electrical system 1 E SECTION E Revision 1...

Page 158: ...USES PAGE 22 SPARK PLUGS PAGE 23 MAIN RELAY PAGE 24 ENGINE PICK UP PAGE 25 TIMING WHEEL GAP PAGE 26 RUN OFF SAFETY SWITCH PAGE 26 INSTRUMENTATION PAGE 27 OIL PRESSURE SENSOR PAGE 28 FUEL LEVEL WARNING...

Page 159: ...connecting a coupling ensure that the body of the coupling is gripped and do not pull it apart by the leads Check that the terminals of the couplings are not slack or bent Check that the terminals are...

Page 160: ...drop semiconductor parts such as those 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 Ele...

Page 161: ...5 Electrical system E 5A 5C 5B ELECTRICAL DIAGRAM F4 1000...

Page 162: ...p switch 36 Right indicator 37 Front headlight 38 Instrument panel 39 Air pressure sensor 40 Left indicator 41 Horn 42 Air temperature sensor 43 Light switch 44 Relay ballast headlight 45 Exhaust valv...

Page 163: ...ATTERY Charge the battery using the current and charging time shown on the battery itself To avoid overcharging the battery we recommend using the constant voltage charging method as speci fied in the...

Page 164: ...otorcycle 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 operati...

Page 165: ...t at a torque equal to 7 8 Nm Afterwards fit the protective cap on the positive pole Torque pressure 7 8 N m 7 Fit the 2 negative terminals on the corresponding battery pole respecting their dispositi...

Page 166: ...e charge after about thirty minutes at the battery terminals Voltage 12 5 Volt 10 Electrical system E Wait at least twenty four hours before positioning the battery in the compartment This is strictly...

Page 167: ...tions 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 th...

Page 168: ...TORE AVVIAMENTO SI RISCONTRANO PROBLEMI SULLO STATO DEL FUSIBILE SUL TELERUTTORE AVVIAMENTO VERIFICARE LA TENSIONE SU TERMINALI DEL REGOLATORE DI TENSIONE SI SI SI SI SI SI SI SI SI SI SI NO NO NO NO...

Page 169: ...A Battery current loss less than 1mA First of all when using an ampmeter utilise a high range of the multi tester because the current losses in the case of malfunctioning could be elevated Do not turn...

Page 170: ...ause will be found in the generator When carrying out this check ensure that the battery is fully charged Feed charge Standard 12 6V 14 5V at 2000 r p m 14 Electrical system E NOTE STARTER SYSTEM The...

Page 171: ...in Engine is starting SOLENOID STARTER BATTERY SERVICE FUSE KEY SWITCH SAFETY SWITCH MAIN RELAY FUEL PUMP COILS INJECTORS RELAY CLUTCH SWITCH SIDE STAND SWITCH NEUTRAL SWITCH TILT SENSOR PICK UP WHEE...

Page 172: ...Engine is starting SOLENOID STARTER BATTERY SERVICE FUSE KEY SWITCH SAFETY SWITCH MAIN RELAY FUEL PUMP COILS INJECTORS RELAY CLUTCH SWITCH SIDE STAND SWITCH NEUTRAL SWITCH TILT SENSOR PICK UP WHEEL F...

Page 173: ...n Engine is starting SOLENOID STARTER BATTERY SERVICE FUSE KEY SWITCH SAFETY SWITCH MAIN RELAY FUEL PUMP COILS INJECTORS RELAY CLUTCH SWITCH SIDE STAND SWITCH NEUTRAL SWITCH TILT SENSOR PICK UP WHEEL...

Page 174: ...continuity between the positive pole and the engine earth If there is no continuity substitute the starter motor STARTER MOTOR REMOVAL Remove the fuel tank see chapter C Bodywork Drain off the engine...

Page 175: ...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 batte...

Page 176: ...multi tester check that the winding is on open circuit or if a resistance is present The wind ing is in good condition if the value of the resistance revealed is as indicated Multi tester dial indicat...

Page 177: ...NGE 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 mul...

Page 178: ...replace the switch proceed as indicated in chapter B Maintenance 22 Electrical system E FUSES The fuses are situated on the left side of the motorcy cle Lift the rubber cover Replace the burnt fuse wi...

Page 179: ...seat Remove the plastic covers on both fuses Substitute the left fuse with the pare one as shown in the figure Fit a new 40A fuse in the spare fuse holder as soon as possible SPARK PLUGS Remove the c...

Page 180: ...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 letter The first thing to check is the isolation between the...

Page 181: ...t 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 After having disconnected the pick up connector mea sure the...

Page 182: ...ising 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 RUN OFF SAFETY...

Page 183: ...und in the instrumentation it is necessary to check the main wiring and the various components assisted by the same instrumentation To carry out the various checks after having removed the fairing sid...

Page 184: ...on tinuity between the contact of the sensor and the earth of the motorcycle as shown in the figure With the engine switched on the contact must be inter rupted FUEL LEVEL WARNING LIGHT CHECK SWITCH A...

Page 185: ...e maximum required for the reser ve WATER SENSOR Verify sensor operation by measuring resistance between the pin by means of a tester TEMP C RESIST k TEMP C RESIST k 40 100 950 40 1 598 30 53 100 50 1...

Page 186: ...n 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...

Page 187: ...hat when the sensor is positioned in front of one of the nuts of the brake disk between terminal 3 and terminal 2 of the connector the voltage is close to zero whilst when it is not placed in front of...

Page 188: ...heck 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 If this is also ok the...

Page 189: ...tors on the left control 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 mo...

Page 190: ...eck the condition of fuse 1 in the fuse box if these are ok replace the bulb Extract the light bulb holder COOLING FAN SYSTEM If there is a fault in the functioning of the cooling fan proceed with the...

Page 191: ...is does not happen check the continuity of the system If this condition is also met the problem lies with the temperature sensor HORN A fault in the horn system should be checked at various points Che...

Page 192: ...36 Electrical system E 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...

Page 193: ...la Pierburg come mostrato in Fig 02 START N B Prestare attenzione al corretto passaggio del tubo valvola Pierburg Fig 01 Fig 02 POSITIONING OF ELECTRICAL SYSTEM WIRE CLAMPS Electrical system 37 E LIST...

Page 194: ...ti sul lato dx della moto vedi Fig 03 Fascetta di protezione Cod 8000B4230 Cod 800092247 L 62 N B Prestare attenzione al corretto posizionamento del nodo e del cavo TPS Fig 03 Fig 04 Insert 1 protecti...

Page 195: ...7 L 62 Cod 800092248 L 82 N B Prestare attenzione al corretto passaggio dei cavi N B Prestare attenzione al corretto passaggio dei cavi Fig 05 Code Code Note Be careful to correctly pass cables Note B...

Page 196: ...blow by Cod 800092248 L 82 Cod 800092248 L 82 N B Prestare attenzione alla corretta fasatura di montaggio del capocorda Cod 800092248 L 82 Fig 06 Code Code Code Note Be careful to ensure correct assem...

Page 197: ...o sx che sul lato dx della motocicletta vedi figg 09 10 N B Posizione nodo di diramazione sul lato dx del telaio Fig 07 Fig 08 Fig 09 Fig 10 Code Note Position the branching node on the right side of...

Page 198: ...esiva cod 8000B4924 sul tubo ant telaio lato sx in modo analogo a quanto sopra descritto per il tubo lato dx Protezione Cod 8000B4924 Fig 11 Fig 12 Position 1 adhesive protection code 8000B4924 on the...

Page 199: ...8000B4425 Cod 800053724 L 39 N B prestare attenzione al corretto passaggio dei cavi N B Prestare attenzione al corretto posizionamento dei cavi Fig 13 Fig 14 Fig 15 Code Code Code Code Screw cap Code...

Page 200: ...gio dei cavi N B Prestare attenzione alla bava sul carter motore N B Prestare attenzione alla bava sulla guarnizione coppa olio Fig 16 Fig 18 Fig 17 44 Electrical system E Code Code Code Note Be caref...

Page 201: ...25 Cod 800056783 plastica Cod 800092247 L 62 Connettore AMP 3 vie fanale post Frecce post Luce targa Fig 19 Fig 20 Fig 21 Fig 22 Fig 23 Code Code 800056783 plastic Code 3 way rear headlight AMP conne...

Page 202: ...io fino a portarla nella posizione indicata Fig 24 Fig 26 Cod 800092247 L 62 Protezione cablaggio Cod 8000B4776 Montare con Guaina di protezione Cod 8000B4963 Fig 25 Loctite 5900 Protection sheat Code...

Page 203: ...tem 47 E N B Prestare attenzione al corretto passaggio dei cavi N B Prestare attenzione al corretto passaggio dei cavi Fig 27 Fig 28 Note Be careful to correctly pass cables Note Be careful to correct...

Page 204: ...48 Electrical system E...

Page 205: ...1 F Suspension and wheels SECTION F Revision 0...

Page 206: ...and wheels SUMMARY FRONT WHEEL PAGE 3 FRONT FORKS PAGE 10 STEERING ASSEMBLY PAGE 25 REAR SUSPENSION AND SWINGARM PAGE 37 REAR WHEEL HUB PAGE 59 MOTORCYCLE SET UP ADJUSTMENT PAGE 75 WHEELS CHECK AND BA...

Page 207: ...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 DUNLOP Sport Max Qualifier RR Front tyre pressure A...

Page 208: ...e material thereby avoiding possible damage to the wheel rim Lift the motorcycle up at the front end Mount the special tool that is supplied with a pin on the lower part of the steering base as shown...

Page 209: ...ach 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 wh...

Page 210: ...able to remove the brake discs as indicated in chapter H Brakes to avoid damaging them Special tool N 8000B4416 Introduce the extractor until the internal ring of the bearing is hooked up Introduce th...

Page 211: ...ings Before proceeding with the reassembly accurately clean the bearing seats in the wheel hub Lubricate the outer ring of both bearings with special grease Mount the bearing on the specific tool and...

Page 212: ...F 8 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 Having comp...

Page 213: ...left Tighten the screw ring of the wheel spindle to the torque prescribed utilising the special tool Ensure that when the wheel is mounted into place the screw ring of the wheel spindle must be on th...

Page 214: ...22 24 Kg m ft lb Torque pressure Operation B A D C B A L I M N F G D C E E H H Description F4 1000 FRONT SUSPENSION Type Upside down telescopic hydraulic fork with external and separated adjustment of...

Page 215: ...Utilise the same procedure for the right clip on handle bar The protection of the clip on handlebars is necessary to stop scratching painted parts of the motorcycle 1 FRONT FORK OVERHAUL Before removi...

Page 216: ...t possible damage Loosen fork plug 1 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...

Page 217: ...elat ed thrust washer Unscrew the plug Using the spanner adjust the spring preload while locking the nut on the damping piston rod Completely unscrew the plug and lower the sheath as shown in the figu...

Page 218: ...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 Remove the central lower screw that fixes the damping piston Keep...

Page 219: ...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 elem...

Page 220: ...e upper bush and extract it Remove the lower bush the washer the oil seal the stop ring and the anti dust seal see figure Extract the fork leg with repeated jerks at the end of its travel Fork assembl...

Page 221: ...al 2 and the anti dust seal 1 from any sharp edges on the lips of the stem during assembly Recommended grease MOLYKOTE 55M Assemble the stem into the sleeve placing the ferrules into their seats with...

Page 222: ...move the damping piston rod up and down until the it slides smoothly Oil type used SAE 7 5 Recommended oil Marzocchi EBH16 SAE 7 5 Check that the oil is at level X with reference to the upper sheath...

Page 223: ...erized 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...

Page 224: ...eassemble the stem taking care to pass the electrical wiring and the clutch tube inside the stem between the stem and the steering head To ensure proper positioning of the rods refer to the figure at...

Page 225: ...y more This operation must be carried for both stems Grease only the first threads Torque pressure 8 9 N m 8 9 N m 1 Ensure that the steering head is sitting perfectly in its seat Tighten the two scre...

Page 226: ...ure After having carried out the assembly of the right clip on handlebar check that the accelerator handgrip rotates freely and smoothly Grease only the first threads Torque pressure 8 10 N m 8 10 N m...

Page 227: ...ing the fork assembly adjust the front suspension so as to ensure optimum vehicle geometry FRONT FORK Substitute oil every 24000 kilometres The front fork is vitally important for the handling and sta...

Page 228: ...si tions Suspension and wheels F 24 Type of set up On road On race track Spring preload 2 turns 5 turns Rebound damping 16 clicks 4 clicks Compression damping 14 clicks 2 clicks NOTE F4 1000 Rebound d...

Page 229: ...STEERING ASSEMBLY A B C D E F G H I N m 120 125 16 18 8 10 4 6 22 24 22 24 8 10 Kg m ft lb Torque pressure Operation I A D H F C B D 270 Suspension and wheels F 25 G E...

Page 230: ...and rest it on the special tool Special tool No 8000B4417 2 Steering head removal After having removed the two fixing screws 1 of the steering shock absorber on the frame loosen the three fixing scre...

Page 231: ...Preliminary operations Disconnect the connectors 1 of the acoustic war ning signal Remove the two fixing screws 2 of the acoustic warning signal support plate and remove the unit Disassemble the hold...

Page 232: ...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 Special tool No 800091645 Remove the screw ring previous...

Page 233: ...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 Remove the ad...

Page 234: ...d steering sleeve see figure and the threaded part with Agip Grease 30 Accurately clean the bearing seats on the frame head steering sleeve Recommended grease Agip Grease 30 Reassemble the frame head...

Page 235: ...t Recommended grease Agip Grease 30 Utilising the special tool tighten the screw ring 1 to the prescribed torque pressure Special tool No 800092857 Torque pressure 120 125 N m During this tightening o...

Page 236: ...one manually Ensure that the steering base is turned as far as pos sible to the right Utilising the special tool tighten the screw ring 1 by rotating it 10 see figure calculable as one third dis tance...

Page 237: ...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...

Page 238: ...screws and extract them When reassembling apply the following tightening torque 22 24 N m F 34 Steering shock absorber connecting rod removal Remove the locknut of the screw 1 that connects the conne...

Page 239: ...essure 8 10 N m 1 8 10 N m 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...

Page 240: ...y operations 1 2 3 16 18 N m 22 24 N m 8 10 N m Tighten the central fixing screw 1 of the steering head Torque pressure 22 24 N m Tighten the two front fixing screws 2 of the steering head Torque pres...

Page 241: ...airing side panels tail unit and fuel tank as described in chapter C Bodywork A B C D E N m 40 44 40 44 40 44 45 50 70 75 Kg m ft lb Torque pressure Operation E B C C A D 243 Description F4 1000 REAR...

Page 242: ...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 1 Slacken the upper...

Page 243: ...Suspension and wheels F 39 Remove the pin 4 of the compensator assembly 5 5 4 Remove nut 3 from the central rocker pin 3 Remove the previously loosened upper screw...

Page 244: ...sion and wheels F 40 Rear shock absorber test Check that the lower and upper bolt holes do not have axial A and radial B play A B Lift the rocker and extract at the same time as the com plete shock ab...

Page 245: ...e until you hear the first click Compressed brake High speed Turn clockwise to end stroke then turn counter clockwise until you hear the first click Compressed brake low speed Turn clockwise to end st...

Page 246: ...haul 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 1 Compensator assembly removal Remove...

Page 247: ...e prescribed torque pressure Special product Loctite 243 Torque pressure 40 44 N m 40 44 N m Rear shock absorber support plate removal Remove the three screw 1 indicated in the figure and remove the s...

Page 248: ...on is necessary to recover the play between the shock absorber compen sator assembly mono arm fork Recommended grease Agip Grease 30 Tighten up the whole assembly Tighten the screws of the connecting...

Page 249: ...s 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 Footrest removal Unscrew the two screws 1...

Page 250: ...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 1 Sile...

Page 251: ...and wheels F 47 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 adj...

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 F 48 1 2...

Page 253: ...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...

Page 254: ...ain 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 CHAIN REMOVAL Cut the chain utilising the special tool Special tool no 8000...

Page 255: ...the pin is out of the chain plate on the wheel side 1 How to fit the chain back in Pick the new connecting link from the package The connecting link is supplied lubricated with a special product that...

Page 256: ...re is more room to work Closing the rivet link Closing the link utilising the special tool Special tool no 8000B1456 Put the assembling tool on the chain placing the cen tering pin between the chain r...

Page 257: ...Using a hammer give a sharp blow to punch 5 to deform the head of the pin Rotate punch 5 approx 90 and repeat operation Release the chain by retracting plate to open the posi tioning rods and continue...

Page 258: ...els F 54 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 cab...

Page 259: ...e of the vehicle Remove the washer and push out the pin manually Support the swingarm so that it does not drop to the ground 1 Upper chain guide removal Remove the two screws 1 and the relative plates...

Page 260: ...y for the bearings on the left side Special tool N 800092860 RIGHT SIDE Bearings overhaul If it is necessary to substitute the bearings of the swin garm because of excessive play operate as follows Re...

Page 261: ...084936 and two new ball bearings Part No 800084938 Preassemble the 2 roller cases Part No 800084936 on specific tool Part No 800092866 see figure Fit the assembly to the left side of the swingarm Asse...

Page 262: ...Suspension and wheels F 58 Utilising a press fit the bearings and the roller bearing units see figure...

Page 263: ...essure Operation 243 243 270 270 243 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 DUNL...

Page 264: ...olygonal nut Utilise the following tools Torque wrench 55 mm polygonal spanner The polygonal fixing nut of the rear wheel has a left hand thread To effectuate the removal it is therefore necessary to...

Page 265: ...shown in the figure Utilise the following tools Torque wrench 55 mm polygonal spanner 1 Slacken the fixings 1 of the wheel hub Remove the screw complete with bushing Extract the chain guard by pullin...

Page 266: ...centric 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 See Motorcycle set up adjustmen...

Page 267: ...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 s...

Page 268: ...rings or chamferings during rotation substitute the wheel hub complete with bearings with a new unit If only one bearing is worn substitute the complete unit Never substitute one bearing only For nor...

Page 269: ...ecommended thread locking fluid Loctite 243 Caliper holder pin torque pressure 30 35 N m Wheel spindle unit check Check the condition of the wheel drive engagement splines If it is worn substitute as...

Page 270: ...assembling apply force on the crown of the peg not on the point see figure Assemble the brake disc carrier plate by tightening the screws to the prescribed torque pressure and then apply Loctite 270...

Page 271: ...bed 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 Check that the coupling bushes of the gear flange sup por...

Page 272: ...and the driving flange 2 do not show any signs of excessive or uneven wear Bushes coupling area 1 Grease AGIP GR SM Bushes coupling area 2 Grease AGIP GREASE 30 Do not apply grease to the threads of...

Page 273: ...eger retaining ring 1 It is important to ensure that the Seeger retaining ring is inserted around the whole circumference of the seat Grease the roller bearing Introduce the first bush the spacer and...

Page 274: ...tite 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 Insert the crown wheel assembly the seco...

Page 275: ...lative 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 Special tool Spanner for eccentric h...

Page 276: ...lower chain pad the upper chain guard and the central exhaust manifolds respectively Rear wheel assembly In the case of substitution of the rear tyre it will be necessary to effectuate the balancing o...

Page 277: ...cover being careful to not extract the clut ch control rod it must remain inserted in the engine and be careful to not lose the two centralising bushes indicated in the figure Straighten the metal ton...

Page 278: ...Recommended thread locking fluid Loctite 243 Remove the chain as described on pages 51 53 Reassemble the pinion wheel cover after having clea ned the support base Screw in the four screws lightly and...

Page 279: ...gure Special tool no 8000B4413 1 Raise the rear part of the motorcycle until the full extension of the rear shock absorber is reached Contemporaneously measure the distance X1 between the upper extrem...

Page 280: ...ing adjuster 3 Repeat these operations until X1 is equal to the refer ence dimension 3 Manually and firmly tighten the two tightening lock nuts of the half supports until you hit the adjuster bar Pres...

Page 281: ...row see figure Calculate static settling using the following formula X1 X2 The static settling value should be 23 mm If static settling differs from the above value perform the following adjustments o...

Page 282: ...wing tolerances Ovalization and maximum eccentricity must not exceed 0 5 mm Flatness must not exceed 0 5 mm When effectuating balancing on certain makes of tyres it is necessary to refer to the yellow...

Page 283: ...g tolerances Ovalization and maximum eccentricity must not exceed 0 5 mm Special tool N 8000A1953 Suspension and wheels F 79 Place the dial gauge as shown in the figure and check the flatness Flatness...

Page 284: ...ertain 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 t...

Page 285: ...Frame 1 G SECTION G Revision 1...

Page 286: ...ATIONS PAG 16 THROTTLE BODY REMOVAL PAG 17 PLUG TOP COIL DISASSEMBLY PAG 22 FRAME DISASSEMBLY PAG 30 FRAME CHECKS AND INSPECTION PAG 32 STEERING SLEEVE HOUSING CHECK PAG 35 FRAME ASSEMBLY ON THE VEHIC...

Page 287: ...rstructures remove the fixing screws of the seat tank support on both sides and remove the bracket Remove the screw 2 indicated in the figure Disconnect the negative pole of the battery When removing...

Page 288: ...4 Frame G 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 Remove the battery from its compartment...

Page 289: ...ary 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 ou...

Page 290: ...e 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...

Page 291: ...rew 2 If the stand plate needs to be removed remove the three fixing screws 3 For reassembly proceed in the reverse order of removal Apply the recommended thread locking liquid to the three plate fixi...

Page 292: ...two screws 1 of both footrest supports and remove them 1 1 EXHAUST SILENCERS DISASSEMBLY Remove the closing wiring cover on the heat guard levering with a screwdriver Extract the wiring and disconnec...

Page 293: ...Frame 9 G Remove the fixing screw 1 of the exhaust valve plate Loosen the lock nuts 2 of the valve opening and clos ing adjusters 2 1 Remove the valve safety plate 1 1...

Page 294: ...valve opening and closing adjuster cables Loosen the screws 2 from the exhaust connection clamp 2 To facilitate silencer dismantling operations remove the rear fixing screw from the central protection...

Page 295: ...rting 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 1 Remove the silencer unit f...

Page 296: ...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 prot...

Page 297: ...Frame 13 G 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 3 4 5...

Page 298: ...ok 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...

Page 299: ...st ports to stop the entry of dirt and dust into the cylin ders 3 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 wheel...

Page 300: ...ckstands 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 ai...

Page 301: ...VAL 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 recov...

Page 302: ...ame G Loosen the upper gas control cable fixing nut 6 Disconnect upper cable from the support Loosen to end stroke the screws 5 of the two pairs of clamps on the suction manifolds as shown in the figu...

Page 303: ...Frame 19 G Loosen the lower gas control cable fixing lock nut 7 Remove the complete throttle body unit 7 Fully loosen the lower gas control fixing nut and remove from the throttle body...

Page 304: ...ing the throttle body 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 suctio...

Page 305: ...f 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 describe...

Page 306: ...22 Frame G 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...

Page 307: ...Frame 23 G 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...

Page 308: ...s 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...

Page 309: ...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 o...

Page 310: ...26 Frame G Disconnect the speed sensor and the rear stop con nector Disconnect the water temperature sensor connector Disconnect the alternator connector...

Page 311: ...Frame 27 G Disconnect the gear sensor connector Disconnect side stand switch connector Disconnect the oil pressure sensor connector...

Page 312: ...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 mot...

Page 313: ...Frame 29 G 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...

Page 314: ...n 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...

Page 315: ...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 a...

Page 316: ...rame 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 co...

Page 317: ...eformed 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 In this case remove the following components Exhaust valve...

Page 318: ...34 Frame G...

Page 319: ...n different points as shown in the diagram 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...

Page 320: ...particular the fairing attachment plates and threaded caps These components can be assembled on the new frame after having carried out a careful inspection Contact MV AGUSTA spare parts service for a...

Page 321: ...Frame 37 G Before proceeding with frame reassembly replace the previously removed electrical wiring and components...

Page 322: ...nator and gear sensor connectors are in position A Make sure that the coil cables are positioned between the suction manifolds 1 2 and 3 4 Make sure the solenoid valve suction tubes B and the phase se...

Page 323: ...60 5 5 6 0 4 8000B2750 Plate frame screw M12x1 25 55 60 5 5 6 0 5 8000B2751 Front fork pin screw M15x1 25 70 75 7 0 7 5 6 8000B2755 Rear suspension compensator screw M10x1 25 45 50 4 5 5 0 7 8D00B269...

Page 324: ...40 Frame G...

Page 325: ...R 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 fro...

Page 326: ...VAL 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 re...

Page 327: ...Frame 43 G 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...

Page 328: ...ition 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...

Page 329: ...Frame 45 G 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...

Page 330: ...46 Frame G Remove the fork pivot spindle fixing nut Remove the rocker spindle from the left side of the motorcycle Remove the right frame plate...

Page 331: ...move 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 th...

Page 332: ...Engine support Remove the following components in order Throttle body page 17 Secondary air valve page 5 Water radiator chapt L Cooling system Exhaust silencers page 8 Exhaust manifolds page 12 48 Fra...

Page 333: ...remove them as shown in the figure 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 t...

Page 334: ...ntrol 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...

Page 335: ...Frame 51 G 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...

Page 336: ...52 Frame G 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...

Page 337: ...G Protect the cover with a nylon cap and remove the two wiring holding clamps Break the chain as described in chapt F Suspension and Wheels and remove the chain from the pinion Rest the cover on the h...

Page 338: ...54 Frame G Disconnect the gear sensor connector and the alterna tor cable connector Disconnect the kickstand connector and the oil pres sure connector Move wiring upward winding it on the frame...

Page 339: ...Frame 55 G 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...

Page 340: ...56 Frame G 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...

Page 341: ...e 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 th...

Page 342: ...Push the engine forward by hand approximately 3 cm Lift the front part of the motorcycle by means of the rel ative front kickstand crank Lower the rear engine support screw in order to turn the engin...

Page 343: ...ion A Make sure that the coil cables are positioned between the suction manifolds 1 2 and 3 4 Make sure the solenoid valve suction tubes B and the phase sensor C are fitted behind the suction hoses Ma...

Page 344: ...f the relative front kickstand crank Insert the two front engine support screws one per part and screw in for only 2 3 of a turn Use the crank to align it for front engine fastening This operation mus...

Page 345: ...Frame 61 G 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...

Page 346: ...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...

Page 347: ...H 1 Brakes SECTION H Revision 0...

Page 348: ...EMOVAL PAGE 10 REPLACING THE BRAKE FLUID TANK PAGE 11 REPLACING THE FRONT BRAKE SWITCH PAGE 13 CLUTCH LEVER REMOVAL PAGE 13 FRONT BRAKE DISCS PAGE 14 FRONT BRAKE DISC REMOVAL PAGE 15 REAR BRAKE SYSTEM...

Page 349: ...t disc thickness mm 5 Min pad thickness mm 1 Brakes 3 H FRONT BRAKE SYSTEM A B C D E F G H N m 2 8 8 10 40 42 23 26 16 18 8 10 23 25 Kg m ft lb Torque pressure Operation It is advisable to remove the...

Page 350: ...towards the outside of the brake pads makes the pistons go back into their seats with the consequent increase in the level of the brake fluid in the brake fluid chamber Move either pad to the centre...

Page 351: ...t of the front back caliper opening then push it towards its pistons Do the same with the other pad Fit the caliper back in but do not tighten the screws Operate the front brake lever to position the...

Page 352: ...eful to not spill the fluid on surround ing parts If the fluid is spilt clean immediately with industrial alcohol and dry with compressed air Remove the protection cap of the bleed valve of the front...

Page 353: ...Utilise only the prescribed brake fluid from sealed containers NEVER use old or used brake fluid Tighten the bleed screw remove the rubber tube care fully clean the screw with alcohol blow it dry and...

Page 354: ...ing a clean cloth Imperfect cleaning of this component could cause the loss of small quantities of brake fluid whilst riding Pour new brake fluid into the chamber until it reaches the maximum level Re...

Page 355: ...rakes 9 H 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...

Page 356: ...de the brake tubing remove the union as indicated in the figure Brake liquid can corrode painted surfaces Clean immediately any spilt brake liquid using industri al alcohol and drying with compressed...

Page 357: ...ctrical 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...

Page 358: ...tighten the screw to the prescribed torque pressure Torque pressure 2 N m When refitting the float chamber use a new fixing screw To substitute the reservoir of the clutch pump operate exactly in the...

Page 359: ...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 CLUTCH LEV...

Page 360: ...f the measurements are below the mini mum substitute the component with a new one 14 Brakes H When reassembling be careful to insert the pin of the pump piston into the seat situated on the lever see...

Page 361: ...ni mum substitute the component with a new one This operation must be carried out on both front discs FRONT BRAKE DISC REMOVAL Take down the front wheel as described in chapter F Suspensions and Wheel...

Page 362: ...contact between the brake discs and the rel ative pads Proceed by reassembling the parts in the reverse order of removal Consult chapter F Suspension and wheels for further information 16 Brakes H 23...

Page 363: ...discs mm 210 Caliper pistons mm With 4 pistons 25 4 Rear disc thickness mm 6 Min pads thickness mm 1 REAR BRAKE SYSTEM Brakes 17 H B E A C F G A B C D E F G H N m 220 240 15 20 16 18 8 10 18 18 20 16...

Page 364: ...Utilising circlip pincers as shown in the figure widen the pads so that the pistons are pushed back into their seats The outward movement of the brake pads provocates the retraction of the pistons in...

Page 365: ...he relative spring 2 Remove the pad 3 by letting it drop down Check the condition of the rear braking system and its components Refit as described for the front braking system Carry out the check ever...

Page 366: ...Open the cover of the rear brake fluid reservoir by removing the two screws 1 Be careful to not spill the fluid from the reservoir during these operations Brake fluid is extremely corrosive Avoid con...

Page 367: ...ches the maximum level Recommended brake fluid AGIP Brake Fluid DOT 4 Utilise exclusively the prescribed brake fluid Use only new brake fluid from sealed containers NEVER utilise old or used brake flu...

Page 368: ...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...

Page 369: ...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 Unscrew the two fixing screws 2 of the brake pump to its relative supp...

Page 370: ...0 NOTE REAR BRAKE DISC REMOVAL Before proceeding with the removal of the rear brake disc it is necessary to carry out certain operations described previously in this chapter Remove the rear wheel Remo...

Page 371: ...least at three points with 120 between them The minimum thickness of the disc must not be less than 5 7 mm Utilise a micrometer gauge for this check Before fitting the rear brake disc check the condi...

Page 372: ...26 Brakes H...

Page 373: ...Cooling system SECTION L Revision 0 L 1...

Page 374: ...ASSEMBLY PAGE 5 WATER RADIATOR COMPONENT DISASSEMBLY PAGE 10 WATER RADIATOR COMPONENT ASSEMBLY PAGE 15 THERMOSTATIC VALVE REMOVAL PAGE 17 THERMOSTATIC VALVE ASSEMBLY PAGE 19 WATER RADIATOR VEHICLE UNI...

Page 375: ...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...

Page 376: ...system and substitute the defec tive damaged parts When removing the tester from the filler hole wrap a cloth around the filler hole to avoid spurts of engine coolant Do not exceed the recommended pr...

Page 377: ...motorcycle 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 t...

Page 378: ...sconnect 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...

Page 379: ...tral radiator fixing screw Remove the upper and lower fixing screws of the radia tor from the left side Special tool CLIC 205 pincers Holding the upper radiator water push the lower radiator oil towar...

Page 380: ...mps at the end of the radiator filling tube on the left side of the motorcycle Special tool CLIC 205 pincers Cooling system L 8 Lower the left side radiator and push it toward the right to remove the...

Page 381: ...e the radiator into an appropriate container Do not dispose of engine coolant in the envi ronment Collect in an appropriate container and dispose of it according the norms in force With the aid of a s...

Page 382: ...NT 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 tub...

Page 383: ...ay 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 Re...

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 L 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 L...

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 L 14...

Page 387: ...with a new one To carry out the above indicated test it is not necessary to remove the fan motors from the engine RADIATOR GROUP ASSEMBLY Before reassembling check the correct rotation of the fans th...

Page 388: ...sure 5 6 N m Replace the previously removed components following the disassembly procedures inversely Cooling system L 16 Recovery tank fixing screws Torque pressure 8 N m Recommended threadlocking pr...

Page 389: ...group should look like the group indicated in the figure The radiator group can be mounted onto the motorcy cle THERMOSTAT REMOVAL Unhook the tube clic clamps of the thermostatic valve and remove the...

Page 390: ...ease in temperature of the thermometer Observe the temperature at the moment of opening of the thermostat The temperature at which the thermo stat commences to open should be between the indi cated va...

Page 391: ...ubsti tute it with a new one Apply a thin layer of silicone grease Recommended grease Silicone Grease Apply grease on the outer flange of the thermostatic valve on the inlet side of the engine Insert...

Page 392: ...ibed 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...

Page 393: ...DIATOR 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 wit...

Page 394: ...em L 22 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...

Page 395: ...he oil radiator support screw from the left side of the motorcycle 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 s...

Page 396: ...er 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 f...

Page 397: ...s with silicone grease Reassemble previously removed components in the opposite order of disassembly The radiator group that has just been assembled should be complete with all parts as shown in the e...

Page 398: ...EM 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...

Page 399: ...ially 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 reins...

Page 400: ...e oil level Ensure that the ground is flat and keep the motorcycle standing as much as possible The level must be near the MAX reference on the timing case as much as possible Do not exceed this limit...

Page 401: ...Special tools 1 M SECTION M Revision 1...

Page 402: ...2 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...

Page 403: ...no per albero Pin for centering di centraggio shaft 9 800092865 1 Attr bilanciamento Rear wheel ruota posteriore balancing tool 10 800095850 1 Pinza montaggio Pliers for clic R smontaggio clamps assem...

Page 404: ...Special tools M 4...

Page 405: ...nteriore Front stand 7 800095808 1 Perno cavalletto Front stand pin anteriore 8 800097887 1 Attrezzo cuscinetto Steering pin perno di sterzo bearing tool 9 800097888 1 Piastra di riscontro Steering ba...

Page 406: ...Special tools M 6...

Page 407: ...00A2385 1 Tampone Guide mounting montaggio guida pad exhaust scarico 19 8000B4368 1 Tampone Guide mounting montaggio guida pad inlet aspirazione 20 800095179 1 Attrezzo Half cones smontaggio disassemb...

Page 408: ...Special tools M 8...

Page 409: ...nit software programming programmazione software centralina CD Rom 31 8000B2118 1 CD Rom per Power unit software programming programmazione software centralina CD Rom 32 8A00B2859 1 Tubo Pipe D39 d27...

Page 410: ...Special tools M 10...

Page 411: ...er sede Pad for exhaust valvola scarico valve seat 6 8000B4566 1 Tampone per sede Pad for intake valvola aspirazione valve seat 7 8000B4309 1 Kit guarnizioni Cylinder head cilindro testa gasket kit 8...

Page 412: ...Special tools M 12...

Page 413: ...1 Tightening torques N SECTION N Revision 1...

Page 414: ...2 Tightening torques N...

Page 415: ...Tightening torques 3 N...

Page 416: ...4 Tightening torques N...

Page 417: ...Diagnostic 1 O SECTION O Revision 0...

Page 418: ...it connection faulty Deoxidize Repair Starting relay switch broken Replace Power cable connections faulty Deoxidize Repair Power unit failure Replace COOLING SYSTEM Electric fans do not work Fuse 5 bl...

Page 419: ...ter temperature gauge does not work Temperature sensor broken Replace Temperature sensor connection faulty Deoxidize Repair Oil warning light does not work Oil pressure sensor broken Replace Oil press...

Page 420: ...n Replace Power relay connection faulty Deoxidize Repair Injector broken Replace Injector connection faulty Deoxidize Repair 7BM injection control unit broken Replace Side stand injector broken Replac...

Page 421: ...Fork oil deteriorated Renew Spring preload low Adjust Hydraulic compression damping insufficient Adjust Fork oil level low Top up Tyre pressure low Adjust Fork damaged Repair Front suspension stiff S...

Page 422: ...iscs distorted Replace Brake pads rub against brake disks Brake pad springs damaged Replace Brake discs distorted Replace Caliper pistons do not slide freely Check Brake fluid level too high Adjust Br...

Page 423: ...Analytical index 1 P SECTION P Revision 1...

Page 424: ...ontrol B 49 Throttles body adjustament and tuning B 51 Transmission chain B 53 Tube band fasteners B 60 Tyres B 56 Valve mechanism adjustment B 15 Wheels B 75 Section C Bodywork Air intake system C 20...

Page 425: ...stment F 75 Rear suspension and swingarm F 37 Rear wheel hub F 59 Steering assembly F 25 Wheels Check and balancing F 78 Section G Frame Assembly frame to the motorcycle G 36 Battery cables G 3 Engine...

Page 426: ...L 26 Radiator group assembly L 15 Radiator group assembly to the motorcycle L 20 Radiator removal L 5 System functioning check L 28 Thermostat L 17 Voltage regulator removal L 11 Water radiator parts...

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MV Agusta F4 1000 S, Workshop Manual

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