MV Agusta BRUTALE 750 ORO, Workshop Manual

Page 1: ...Motorcycle Workshop Manual MVAGUSTABRUTALE ORO S ...

Page 2: ... 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 to consult this manual with regards to the sequences of removal demonstrated in this manual Informative note MV Agusta S p A is committed to a policy of continuous improvement of their products For th...

Page 3: ...E INJECTION SYSTEM ELECTRICAL SYSTEM SUSPENSION AND WHEELS FRAME BRAKES COOLING SYSTEM AND LUBRICATION SYSTEM SPECIAL TOOLS TORQUE PRESSURES DIAGNOSTICS ANALYTICAL INDEX A Rev 0 B Rev 1 C Rev 0 D Rev 0 E Rev 0 F Rev 1 G Rev 0 H Rev 0 L Rev 0 M Rev 0 N Rev 0 O Rev 0 P Rev 0 ...

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Page 5: ... 1 General description A SECTION A Revision 0 ...

Page 6: ...A SUMMARY HOW TO CONSULT THIS MANUAL PAGE 3 PURPOSE OF THE MANUAL PAGE 3 GLOSSARY AND SYMBOLS PAGE 4 RIGHT HAND AND LEFT HAND STANDARD PAGE 5 SAFETY PAGE 6 WARNING PAGE 8 INDEX PAGE 8 OPERATIVE TECHNICAL SPECIFICATIONS PAGE 9 ...

Page 7: ...dure special 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 dealers and qualified mechanics It is not possible to document all the knowledge necessary for a mechanic in a manual Those who utilise it must have a basic knowledge of mechanical concepts an...

Page 8: ...fic 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 the recommended oil Use the recommended grease Use the recommended 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...

Page 9: ... RIGHT HAND AND LEFT HAND STANDARD In order to specify the right left convention used within the chapters of this manual see the following motorcycle and engine scheme where all sides which refer to are reported A Cylinder 4 Cylinder 3 Cylinder 1 Cylinder 2 Right side Left side Right side Left side ...

Page 10: ... 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 Ethylene glycol would cause serious burns if ignited because it is invisible Avoid bringing the engine coolant into contact with hot parts Such parts could be sufficiently hot to ignite the coo lant The eng...

Page 11: ...surise 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 consequent burns Keep out of reach of children Battery The battery produces explosive gases Keep it away from sparks flames or cigarettes During recharging adequa tely ventilate the environment The batt...

Page 12: ... place them 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 scribed Respect the instructions about their technical characteristics Always substitute parts such as gaskets O rings security washers with new parts Loosening and tightening nuts or screws alwa...

Page 13: ...e 4 numero serie limitata 1 numero di matricola telaio 3 dati di omologazione Only for the F4 BRUTALE series ORO the pre sence of the nameplate indicates that the motorcy cle has been constructed on a limited series basis Each example is identified by a progressive num ber stamped on a nameplate in 24 carat gold ZCG F4 01 AA Y V 000000 Manufacturer identification Vehicle model Progressive frame nu...

Page 14: ... 10 General description A ...

Page 15: ...B 1 Maintenance SECTION B Revision 0 ...

Page 16: ...EL UNION TUBES PAGE 47 FUEL TUBES ASSEMBLY PAGE 47 THROTTLE BODY ADJUSTMENT AND TUNING PAGE 50 AIR FILTER PAGE 57 BRAKES AND CLUTCH PAGE 60 BRAKE CLUTCH GEARCHANGE COMMANDS CHECK PAGE 63 BRAKE PADS PAGE 65 ACCELERATOR CONTROL PAGE 65 LOCKS PAGE 67 STEERING PAGE 69 TRANSMISSION CHAIN PAGE 69 TYRES PAGE 72 FRONT WHEEL BEARINGS PAGE 72 WHEELS PAGE 73 REAR WHEEL HUB PAGE 74 OSCILLATING ARM BEARINGS PA...

Page 17: ... kg 3 5 3 5 ENGINE Type 4 Stroke four cylinder 16 valves Bore mm 73 8 73 8 Stroke mm 43 8 43 8 Displacement cm3 749 4 749 4 Compression ratio 12 1 12 1 Starter system Electrical Cooling Liquid with oil cooler Engine casing and covers Die cast Cylinder head and cylinders Chill cast Valves Bi metal mono metal I The data declared are not binding They are susceptible to variations due to riding condit...

Page 18: ...th a system of external adjustment for extension compression and spring preload Ø stems mm 50 with titanium nitride treatment 50 Telescopic movement mm 128 128 REAR SUSPENSION Type Progressive single steering damper adjustable in extension in compression high low speed and in spring preloading Mono arm fork Magnesium alloy Aluminium alloy Wheel travel mm 120 120 FRONT BRAKE Type Floating double di...

Page 19: ... conveyors Carbon fibre Thermo plastic material Tank side panel Carbon fibre Thermo plastic material Tail unit rear side panel Carbon fibre Thermo plastic material Tail unit Carbon fibre Thermo plastic material Instrumentation protection Carbon fibre Thermo plastic material Ignition switch cover Carbon fibre Thermo plastic material Exhaust tube protection Carbon fibre Thermo plastic material Chain...

Page 20: ...h cover 9 Tail unit 10 Front mudguard 11 Top chain protection 12 Lower chain protection 13 Oil cooler protection 1 Right air filter compartment side panel 2 Left air filter compartment side panel 3 Right tank side panel 4 Left tank side panel 5 Right cylinder cover 6 Left cylinder cover 7 Instrument panel protection ...

Page 21: ...Maintenance 7 B MAGNESIUM COMPONENTS F4 BRUTALE ORO 1 Steering base 2 Frame side plate 3 Front wheel rim 4 Rear wheel rim 5 Mono arm fork 4 1 2 3 2 5 ...

Page 22: ... 8 Maintenance B ...

Page 23: ...Description Operation Km mi covered Service A B C D E F G Programmed maintenance schedule Substitution Utilise only originali MV Agusta oil filters Cleaning of contact lever pump piston area front and rear Engine oil Substitution At least once a year Engine oil filter At every substitution of engine oil Engine coolant Check level and top up Substitution At least every two years Cooling system Chec...

Page 24: ...r pressure Check for wear Wheel rims Visual check Every tyre substitution Check Front wheel bearings Every tyre substitution Substitution Parts in magnesium Visual check for knocks and scratches At least every six months Side stand Check functioning Side Check functioning stand switch Rear wheel hub Check Substitution Rear fork bearings Check lubricate Rear fork chain guide Check substitution Chai...

Page 25: ...te container Do not scatter the drainage oil into the envi ronment 11 B N B Description Recommended product Specification Engine oil AGIP RACING 4T 10W 60 SAE 10W 60 API SJ Ethylene glycol Engine coolant AGIP ECO PERMANENT diluited with 40 distilled water Brake and clutch fluid AGIP BRAKE FLUID DOT4 DOT4 Chain lubrication oil MOTUL CHAIN LUBE PLUS Table of lubricants and fluids To find the recomme...

Page 26: ...ystem is completely empty of used engine oil Substitution of the oil filter In order to proceed to replace the oil filter you should remove the exhaust manifolds of the cylinders 3 and 4 Release the two side clamps of the oil cooler Unscrew the lower fixing screws of the oil cooler pro tection on the lower basis of the water radiator Remove the oil cooler protection ...

Page 27: ... between compensator and manifolds of cylinders 3 and 4 13 B 20 22 N m Remove the manifold of cylinders 3 and 4 In order to facilitate the reassembly of the manifolds you should place the fixing flan ge on the manifolds before these manifolds are pleced on the engine Insert the flange in the manifolds and then turn it Place the flange manifolds assembly on the fixing stud then tighten the check nu...

Page 28: ...ent of a filter branded TOYO ROKI use the wrench for oil filter TOYO ROKI FACOM D 139 tool Part code 8000A4317 In the event of a filter branded Champion use the wren ch for oil filter Champion Part code N 800099010 Clean accurately any oily parts Using a clean cloth to clean accurately the area and the filter face ...

Page 29: ...n oil filter Toyo Roki Part code 8000A3702 you should the following preliminary ope ration Take out the gasket from the engine oil filter kit of new equipment and insert on the filter as shown in the figu re on the left Only use a new gasket Slide the gasket up to bring in contact with the oil filter back ring see figure on the right Lubricate the gasket on the filter with engine oil Maintenance 1...

Page 30: ...OKI oil filter FACOM D 139 tool Part code 8000A4317 Oil filter torque wrench 24 N m Champion oil filter Tool code 800099010 Oil filter torque wrench 15 N m After having tightened the filter take out the clamp for engine oil filter and its screw from the new oil filter kit Only use a new clamp Insert the clamp and slide it until it brings in contact with the oil filter back ring TOYO ROKI 24 N m Ch...

Page 31: ... the position marked previously 1 1 5 mm Once completed the assembly ensure that the clamp lock of the engine oil filter is at a range between 1 and 1 5 mm from the screwhead on the supporting plate of oil cooler pipes Check any leakages from oil filter Mark the position of the definite tightening of the screw using a felt pen both on the filter and the band faste ner Trace a reference mark also o...

Page 32: ...Ensure that the motorcycle is placed on level ground and is in a vertical position The correct level must be as close as possible to the MAX mark shown on the engine casing Do not sur pass this limit Check any oil leakages Avoid turning the engine over with the oil level lower than minimum It could compro mise the correct functioning of the engine If the level after the topping up is over the MAX ...

Page 33: ...from the ope ning on the frame protection panel on the left side of the motorcycle 3 2 If the level is under the minimum line proceed with top ping up as follows Remove the two fixing screws 2 of the ignition switch cover 3 Extract the cover 4 With the engine cold top up the level using the filler hole 4 of the expansion tank Open the expansion tank only when the engine is cold the discharge of bo...

Page 34: ... N m Fill the cooling system with the appropriate liquid described in table see page 11 of this chapter until the level is between the MIN mark found on the expansion tank and the lower part of the frame tube see figure below Close the cap Switch on the engine and keep it running until the water becomes hot enough to automatically switch on the electric cooling fan Switch off the engine Wait some ...

Page 35: ...s To carry out the check on the functioning of the electric cooling fan switch on the engine and heat it up The electric fan should come into operation when the instrument panel shows a system temperature of about 100 C If the electric cooling fan does not switch on carry out the checks on the various components as described in chapter L Cooling system 21 B ...

Page 36: ... in this manual An analogous reference is utilised for the reassembly of the parts after the maintenance operation After having removed the indicated components the motorcycle is shown in the condition described by the photograph on the left Before proceeding with the various maintenance ope rations it is advisable to thoroughly wash and clean the motorcycle Place the motorcycle now without the co...

Page 37: ... to the air intakes of the engine A B Apply adhesive tape also on the oil breather tube A and on the terminals of the accelerator control B Pull out the connectors of the coils In order to perform this operation release the secon dary lock yellow tongue pulling out from its seat then press the black tongue and release the connector 23 B ...

Page 38: ...e coil harness from the frame removing the two clamps and extract it on the right side Unscrew the fixing screws of the coil plates and remo ve them Pull out the coils from their seat Screw and remove the eight fixing bolts of the cylinder head cover 24 Maintenance B ...

Page 39: ...rate the motorcycle parts in the proximity of the work area Proceed with the removal of the cylinder head cover To facilitate this operation it is advisable to move the rubber engine coolant filling tube situated on the left side of the motorcycle Complete the removal of the cylinder head cover by sli ding it towards the rear part of the motorcycle 25 B Remove the head cover gasket ...

Page 40: ... the Top Dead Centre position T D C when the piston is at its uppermost part of the compression stroke Utilising a syringe remove the surplus oil that is left in the various niches in proximity to the valve cups Proceed with the removal of the timing wheel cover by unscrewing the five fixing screws 26 Maintenance B ...

Page 41: ...aph illustrates clearly the correct position The position of the timing wheel is clearly seen in the enlargement in respect of the mark on the engine casing Also the marks present on the toothed wheels of the camshaft must be aligned together when the timing wheel is in this position 27 B Utilising a feeler gauge of the type shown in the figure measure the play between the camshaft and the valve c...

Page 42: ...Continue measuring the play as illustrated in the figu re The correct measuring of the play is a funda mental operation for the correct functioning of the engine 28 Maintenance B ...

Page 43: ... Valve n 4 Valve n 5 Valve n 6 Valve n 7 Valve n 8 Valve play Pad thickness CYLINDER 1 CYLINDER 2 CYLINDER 3 CYLINDER 4 EXHAUST Valve n 16 Valve n 15 Valve n 14 Valve n 13 Valve n 12 Valve n 11 Valve n 10 Valve n 9 Valve play CYLINDER 1 CYLINDER 2 CYLINDER 3 CYLINDER 4 EXHAUST Valve n 16 Valve n 15 Valve n 14 Valve n 13 Valve n 12 Valve n 11 Valve n 10 Valve n 9 Valve play Pad thickness Values mea...

Page 44: ...r 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 pre viously illustrated Rotate the crankshaft 360 by turning the central nut The rotation of the crankshaft must always be done in an anti clockwise direction The operation just described is completed when piston n 4 is in the Top Dead Centre po...

Page 45: ...e tooth on the engine casing Continue with the measuring of the play of the fol lowing valves Cylinders 3 and 4 intake valves n 5 6 7 8 Cylinders 2 and 4 exhaust valves n 9 10 13 14 Make a note of the measured values ensuring that they are scrupulously written in the correct order of the pre viously illustrated table 31 B ...

Page 46: ...e manual Code 8000A1592 If the values are correct reassemble in reverse order to disassembly Consult the F4 workshop engine manual Code 8000A1592 for the specific torque pressures and the necessary products Before proceed to reassemble the engine head cover it is recommended to clean accurately the residues of dope along the seal form on the head and use a new gasket 32 Maintenance B Camshaft Valv...

Page 47: ... kilometres at 6000 kilometres and then every 12000 kilometres Substitute Every 12000 kilometres The following components must be removed to accede to the spark plugs Passenger seat Rider seat Fianchetto laterale sx Right side panel Fuel tank Air filter compartment Proceed to pull out 4 coils as described above Remove the spark plugs utilising the appropriate 16 mm hexagonal spark plug spanner Hea...

Page 48: ...gs into their seats to avoid damage to the threading of the cylinder head When com pletely screwed in by hand tighten to the specified torque pressure Spark plugs torque pressure 12 N m FUEL FILTERS Check and substitute Every 12000 km For the checking or substitution of the engine intake system filters fuel filter fuel pump filter it is neces sary to remove in sequence the following parts Passenge...

Page 49: ...at 1 1 1 1 35 B 1 1 1 2 To pull out the flange 2 use three M6 screws 1 remo ved previously Insert the screws 1 into the respective threaded holes Screw in sequence until the flange is extracted 1 2 Lift up the flange 1 and disconnect the tubes 2 on both sides of the flange Remove the two CLIC R 96105 fasteners utilising the specified pincers Specified pincers CLIC R 205 Part code 800095850 ...

Page 50: ...rings 1 of the flange 2 and clean them accurately Check they are undamaged If damaged replace them with new rings 1 Disconnect the electric connectors of the fuel pump 1 1 Extract the complete flange assembly 1 36 Maintenance B ...

Page 51: ...a tube spanner on the fixing nut of the probe 37 B 1 Remove the closing screw 1 of the conduit indicated in the figure so that the remaining fuel flows out of the conduit 1 Remove the two CLIC R 96135 fasteners 1 placed on top of the fuel filter ...

Page 52: ...1 Remove the fuel filter 1 1 Extract the fuel pump 1 from its seat 1 Operate as indicated in the preceding figure and remo ve the CLIC R 96135 fastener 1 38 Maintenance B ...

Page 53: ...ny residue and ensure that there are no sha vings that have originated from mechanical work 1 Degrease the threaded hole and the screw 1 with the appropriate solvent as shown in the figure Clean and dry by blowing with compressed air Apply LOCTITE 542 thread locking fluid Reassemble the screws and tighten to the specified torque Specified product LOCTITE 542 Torque pressure 10 N m 10 N m ...

Page 54: ...ged 1 Assemble the CLIC R 96 135 fastener 1 green colour onto the tube as shown in the figure Using fine abrasive paper clean the first threading cre sts of the fuel probe seat as shown in the figure This operation is necessary to not compromise the good condition of the gasket during the assembly phase of the probe 40 Maintenance B ...

Page 55: ...n the figure If necessary utilise alcohol to facilitate the assembly Tighten the CLIC R 96 135 fastener 2 green colour utilising the CLIC 205 pincers 41 B 1 Insert the connection pipe of fuel filter pump using alcohol in order to facilitate the assembly Assemble the CLIC R 96 135 fastener 1 green colour using the CLIC 205 pincers 1 Insert the pump into its seat ...

Page 56: ... grease also on the threa ded seat of the probe Tighten the probe so that the output position of the electrical wiring is in correspondence with the centre line of the writing FRONT between the two arrows 1 Insert the pipe on the fuel pump Facilitate the insertion using alcohol Assemble the CLIC R 96 135 fastener 1 green colour using the CLIC 205 pincers 42 Maintenance B 1 2 ...

Page 57: ...sembly of the flange group 1 inser ting the sealing O Rings 2 in their seat Before assembling verify that components are undamaged and lubricate them applying silicone grease It is recommended to apply a layer of silicone grease on the seat of the die cast flange The use of worn O Rings can cause any fuel leakage from the tank motorcycle and fire risk for the motorcycle as a consequence Carry out ...

Page 58: ... 44 Maintenance B FUEL PUMP ASSEMBLY ...

Page 59: ...3 800021480 1 4 80A090925 1 5 800090925 1 6 800090939 2 7 8000A1400 1 8 800090919 1 9 800090920 1 10 800093410 1 11 800093411 1 12 800090921 1 13 800098305 1 14 8M0092249 2 15 8S0092249 2 16 8E0087431 1 17 8H0087431 1 18 800088585 1 19 800090929 1 20 800093323 1 21 800093324 1 22 800090930 1 23 800098304 1 ...

Page 60: ...sub stitute them and position the band fasteners as shown in the figure 1 2 Position the flange unit 1 inside the fuel tank Check that the two small overflow tubes 2 remain out side of the fuel tank Specific pliers CLIC R 205 Part code 800095850 1 2 Insert two CLIC R 96 105 band fasteners 1 onto the small tubes Insert the two small rubber tubes 2 onto the appropriate spigot on the die cast flange ...

Page 61: ...NION TUBES Check for leaks First 1000 kilometres and then every 6000 kilometres Carry out a visual check for eventual leakages from the fuel feed tubing and the unions see figure Substitute damaged parts if leaks or evaporation are found FUEL TUBES 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 orde...

Page 62: ... of the butterfly body The fuel tube with the black CPC union is assembled on the left side of the butterfly body Follow the indication shown in the figure Orientate the CPC unions as shown in the figure During the check distend the tubes to eliminate flexions and deformation of the same ...

Page 63: ... can be opened Ensure that the two tubes are of equal length and posi tion the fasteners so that they are exactly aligned with the frame tube see the figure Conclude the operation by reassembling the compo nents in reverse order of disassembly Ensure that the tubes are correctly fitted onto the metal unions of the butterfly body and check that the rubber tubes do not cover the curved section of th...

Page 64: ... perfor mance of the engine When carrying out operations on throttle bodies it is advisable to remove certain parts of the bodywork such as Passenger seat Rider seat Tank side panels Ignition switch cover Fuel tank Attention before adjusting the throttle body verify accurately the absence of any cracks or damages on the pipes to check the depression the absence of gas leakages from drain pipes joi...

Page 65: ...right side of the motorcycle near the expansion tank of the coolant Start the MDST diagnosis software and go to the Display instrument panel screen Set the ignition switch to ON Select the Connect option from the toolbar Now the software displays the main operating parameters of the injection ignition system verify that the temperature and pressure sensors have coherent readings ...

Page 66: ...e throttle opening using only the appropriate screw on the throttle opening pulley It is recommended not modify the throttle potentiome ter position because the throttle has been set during the production to the optimal value Remove the sealing caps of the small tubes to check the vacuum pressure The number of the cylinder to which the caps are con nected is written on the caps The small tubes for...

Page 67: ... 2 probes registering CO inside the specific tool kit code 8000A4686 Assemble the 2 pipes with their Y union also supplied with tool kit code 8000A4686 on the probes registe ring CO Connect the Y union with a rubber pipe to the exhaust gas analyser Verify that the ignition switch is set to OFF Disassemble the injection ignition gearcase placed on the air filter compartment unscrewing the four fixi...

Page 68: ...crews and then open them for 1 turn again Start the engine and warm it up During this phase you should not accelerate because the high depression created in the induction lines could pipe the mercury from vacuometer The engine rotation can be supported by using the starter The attainment of the correct thermal speed is given by the intervention of the cooling fan ...

Page 69: ... be between 1 and 1 5 rpms from the fully closed position Keeping the depressions aligned adjust the engine speed with fan connected and light on so it is between 1100 and 1200 rpms Check the CO value using the exhaust gas analyser This value must be between 3 and 4 If the CO value does not fall into the established values operate the trimmer inside the gearcase until the values fall into the tole...

Page 70: ...erform in the order as follows assemble the rubber plug on the gearcase lower side apply a new seal plate assemble the gearcase on the air filter compartment restoring the earth bonding disassemble the exhaust gas probes and tighten the fixing screws restore the sealing caps of drives for checking depression reassemble tank tank side panels ignition switch cover rider seat and passenger seat After...

Page 71: ...e before acceding to the air filter See chapter C Bodywork Passenger seat Rider seat Left tank side panel Right tank side panel Ignition switch cover Fuel tank Air filter compartment 1 Remove the sealing rubber gasket 1 Work on the three tongues of the air filter and extract it from the air filter compartment ...

Page 72: ...e of the air filter compartment is clean and free from foreign bodies Insert the air filter complying with the correct assembly direction shown in the figure Press in the three fixing tongues until a click is heard Complete the assembly of the filter into the air filter compartment sealing the operation opening by the rub ber gasket as shown in the figure ...

Page 73: ...ply silicone grea se to the gaskets of the air intake bell chambers Proceed with the assembly of the parts listed below and according to the procedure described in chapter C Bodywork Air filter compartment Fuel tank Right tank side panel Left tank side panel Ignition switch cover Rider seat Passenger seat ...

Page 74: ...e the motorcycle in a vertical position with the handlebars straight Check the fluid levels in the brake and clutch fluid chambers observing the lines for the level marked on the chambers If the level is lower than the lower level line add brake fluid complying with the specification by the manufac turer in according to the following procedure Remove the 2 screws from the fluid tank cover Remove t...

Page 75: ...efore completing the operation clean and wash accu rately the 3 components of the chamber cover using alcohol and blow to dry them Clean the edge of the fluid chamber with a clean cloth Close the fluid chamber with the two relative screws Imperfect cleaning of these parts could cause the discharge of small quantities of brake fluid during riding Brake fluid has strong corrosive properties ...

Page 76: ...ely discolour painted surfaces Before riding check the tubes and joints of the brakes for damage and signs of leaks Substitution and bleeding of the brake clutch fluid The substitution of the brake clutch fluid and the suc cessive bleeding of the circuit are operations that require particular caution and precision To carry out these operations it is therefore necessary to follow the procedure desc...

Page 77: ...d 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 the spring and at the same time adjust the position by rotating the ring in a clockwise or anti clockwise direction In a clockwise direction The lever goes further away from the handgrip In an anti clockwise...

Page 78: ...st adjustment On the BRUTALE ORO model the footrests are adju stable Operate as follows for the adjustment from the original position Slacken without removing the eccentric adjustment screw situated at the rear of the footrest support using a 12 mm hexagonal spanner Loosen without remove the two fixing screws of the frame board support using a 6 mm setscrew wrench 6 N m 24 28 N m Lay without tight...

Page 79: ...effi ciency 1 ACCELERATOR CONTROL Accelerator play check At the pre delivery check at the first 1000 kilometres and then every 6000 kilometres The accelerator control should not be too tight or too slack excessive play in its movement It must also be free of play and looseness when turning it For optimum adjustment it is necessary to work on the two upper nut adjusters situated on the accelerator ...

Page 80: ...ottle bodies the transmission of the accelerator control must be analysed not only at the accelerator handgrip but also near to the throttle bodies It is therefore necessary to consult chapter D Air intake injection system As a final control and after having reassembled all the components switch on the engine and check that with the choke lever activated the tickover of the engine does not exceed ...

Page 81: ...be switched on The 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 the handlebar left or right Press the key down and rotate it to the LOCK position All electrical circuits are disactivated and the steering is blocked The key can be pulled out P po...

Page 82: ... with a new one as described in chapter C Bodywork Personal compartment lock Insert the key in the lock Turn the key clockwise and at the same time press the passenger seat slightly Lift and take out the passenger seat For reassembling the part refer to the following indica tions Turn the key in the lock Press the passenger seat Release the key Press again the passenger seat verifying it is well f...

Page 83: ...The clearance h between the axis of symmetry of the chain and the chain cover should be equal to the fol lowing values as shown in the figure BRUTALE ORO S MY 03 h 6 mm BRUTALE S MY 04 h 11 mm Manually rotate the rear wheel and effectuate this check on more than one point of the chain The play must be constant whilst the wheel turns If the chain is slack in only certain places means that the some ...

Page 84: ...g or tightening the chain until the correct play is reached as described previously Successively tighten the screws of the rear wheel hub to the torque pressure indicated as follows Rear hub eccentric adjuster screw torque pressure 28 32 N m After tightening the screws of the rear wheel hub recheck the chain tension so that any eventual varia tions can be found If the tension of the chain is varie...

Page 85: ...r to avoid damages you should not clean the chain using jets of steam or high pressure water or using fuel or cleansing solvents on the market Then apply a light and even coating of lubricant on the whole chain without reaching the surrounding parts in particular the tyres Use only the lubricant recommended see page 11 in this chapter in order to effecti vely protect the gearing chain and avoid fr...

Page 86: ...I Diablo Corsa Race Replica MICHELIN Pilot Sport MICHELIN Pilot Power DUNLOP Sport Max D 207 Race Replica Inflation pressure Front 2 3 bar 33 psi 2 3 bar 33 psi Rear 2 3 bar 33 psi 2 3 bar 33 psi The use of the motorcycle with excessively worn tyres diminishes the roadholding and is therefore dange rous It is highly recommended to change the tyres when the tyre tread reaches the following minimum ...

Page 87: ...ery 6000 kilometres at least every tyre change After having visually checked or following even light collision damage it is necessary to check the planarity the eccentricity and the ovalisation of the wheel See the control procedures described in chapter F Suspension and wheels ...

Page 88: ...act the wheel pin Check and overhaul the rear wheel hub unit see chap ter F Suspension and wheels OSCILLATING ARM BEARINGS Check and lubricate Every 36000 kilometres If excessive play is found on the rear fork due to the bearings assembled on the central pin of the fork frame substitute them as described in chapter F Suspension and wheels A REAR SHOCK ABSORBER Check and adjust At the first 1000 ki...

Page 89: ...llowing procedure Disconnect the electrical connectors Remove the 2 fixing screws of the switch Remove the switch After having substituted the switch tighten 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 side stand operate as follows After having removed the side stand s...

Page 90: ...ap ter F Suspension and wheels SCREWS AND NUTS Check and tighten At the pre delivery at the first 1000 kilometres and then every 6000 kilometres Carry out an accurate check of the tightness of the nuts and screws on the motorcycle at the intervals prescri bed Consult the table in chapter N Torque pressures for the correct values TUBE BAND FASTENERS Check and tighten At the pre delivery at the firs...

Page 91: ...e tres Consult chapter E Electrical system for the check on the battery condition If it is necessary to disconnect the battery and remove it during overhauls carried out on the motorcycle follow the procedure in the figure for the correct assembly Insert the battery in the proper compartment The first charge of the battery must be performed before assembling it on the motorcycle Assembly of the ba...

Page 92: ...que by using a torque wrench Torque wrench setting 7 8 Nm When the leads are mounted replace the protection cover on the positive pole see the figure Mount the two negative terminal leads on the relati ve pole of the battery following the placement shown in the figure 78 Maintenance B 7 8 N m ...

Page 93: ...entati vedi figura CAVO NEGATIVO POSIZIONAMENTO E MONTAGGIO DEI TERMINALI CAPICORDA SULLA BATTERIA POLO NEGATIVO CAVO POSITIVO ATTENZIONE Alla fine dell ope razione di montaggio assicurar si che il cavo del terminale posi tivo sia posizionato all interno della struttura del telaietto poste riore vedi figura 79 B 7 8 N m PLACEMENT AND ASSEMBLY OF TERMINALS WIRE TERMINALS ON THE BATTERY NEGATIVE WIR...

Page 94: ...ning light green It lights up when the direction indicators are activa ted 5 Fuel reserve warning light orange It lights up when the fuel tank contains approxima tely four litres of fuel 6 Engine oil pressure warning light red It lights up when the oil pressure inside the oil lubri cation system is insufficient If the oil pressure warning light lights up whilst riding the motorcycle stop immedia t...

Page 95: ...r in Fahrenheit F The temperature field goes from 40 C to 140 C 104 F to 284 F under 40 C 104 F the indication does not appear Three flashing lines appear which means that the temperature signal is very low between 40 and 49 C 104 and 120 F the indi cation flashes wich means that the temperature is low between 50 C and 105 C 122 F and 221 F the indication is fixed between 106 C and 140 C 223 F and...

Page 96: ...tain the quick scrolling of the selected digit press and hold the engine starting but ton more than two seconds Repeat the procedure for the second figure of the hour for the first and second figures of the minutes Press the SET button to confirm the figures and to interrupt the selection the flashing Speedometer k p h m p h Repeatedly press the starter button until the visualisa tion of the TOTAL...

Page 97: ...e ther mometer starts to flash Proceed to the successive adjustment Thermometer C F Press the starter button to pass from C to F and vice versa Press the SET button to confirm the measuring unit Display function selection The selection of the TOTAL mileometer the partial TRIP 1 mileometer the partial TRIP 2 mileometer and the clock must be carried out with the engine swit ched on Repeatedly pressi...

Page 98: ...our seconds the value zeroes If instead the starter button is pressed for more than four seconds the resetting procedure is interrupted Pressing the engine starting button activate the func tion TRIP 2 Press the engine starting button for more than four seconds the value starts to blink Now pressing the engine starting button for less than four seconds the value is set to zero If you press the eng...

Page 99: ...e burnt out replace them as follows 1 Dipped headlamp bulb substitution Remove the two side fixing screws 1 of the front headlight Pay attention to take out the register from the proper seat when the headlamp is removed from the support 2 Before removing the front headlight from its support disconnect the connector 2 placed on the back of the headlamp 85 B ...

Page 100: ... of the dipped headlight Do not touch the glass of the bulb with your hands In case of contact clean using a degreasing product Insert the new bulb Refasten the check spring Place the protection cover again Reconnect the connector of the dipped headlight Reassemble the front part of the headlamp from its support shell Retighten the back screw Reinsert the connector of the headlamp Place the headla...

Page 101: ...g counter clockwise Reassemble the headlamp on its support Front lights Replacing bulb Remove the front headlamp from its support Turn the lamp holder counterclockwise and extract it from its seat Extract the bulb removing it from lamp holder Do not touch the glass of the bulb with your hands In case of contact clean using a degreasing product Insert the new bulb Reinsert the lamp holder in its se...

Page 102: ...ng it clockwise Reassemble the glass and retighten the fixing screw Rear direction indicators bulb substitution Remove the fixing screw Remove the glass To extract the bulb press it counterclockwise Insert the new bulb pressing and turning it clockwise Reassemble the glass and retighten the fixing screw ...

Page 103: ...g it in an anti clockwise direction To extract the bulb press it down and rotate it in an anti clockwise direction Insert the new bulb pressing and turning it clockwise Reinsert the bulb holder and rotate it in a clockwise direction Number plate light bulb substitution Remove the fixing screws of the cable guide ...

Page 104: ...the lamp holder of the number plate light from its seat Extract the bulb taking it out from the lamp holder Insert the new bulb Reinsert the lamp holder Place the cable guide again into contact with the upper supporting surface Retighten the fixing screws of the cable guide Fuses Substitution The recharge fuse is under the rider seat as shown in the figure ...

Page 105: ...ion switch on OFF before checking or replacing the fuses in order to avoid accidental short circuits with conse quent risk to damage other electric compo nents To identify the position and the function of the fuses consult the information on the adhesive label and the electrical system The reference letters indicated in the figure correspond to those shown in the electrical dia gram ...

Page 106: ...ent fire risk FRONT HEADLAMP Check adjustment At every variation of the motorcy cle set up Each time a variation to the set up of the motorcycle is carried out it is good practice to carry out the adjust ment of the headlamp beam The adjustment of the front headlight can be perfor med operating the screw shown in the side figure Clockwise the headlight leans downward Counterclockwise the headlight...

Page 107: ...perpendicular to the wall The motorcycle must be in a vertical position Measure the height of the centre of the beam from the ground and mark it with a cross on the wall using a piece of chalk Switch on the dipped beam The upper demarcation limit between the dark zone and the illuminated zone must be not more than 9 10ths of the height from the ground of the centre of the beam ...

Page 108: ... 94 Maintenance B ...

Page 109: ... 1 Bodywork C SECTION C Revision 0 ...

Page 110: ...SSEMBLING HANDLEBAR Page 6 DISASSEMBLING HEADLIGHT SUPPORT Page 7 FUEL TANK Page 8 DISASSEMBLING FUEL TANK SIDE PANELS Page 9 FUEL TANK REMOVAL Page 10 AIR FILTER COMPARTMENT Page 15 AIR FILTER COMPARTMENT REMOVAL Page 16 TAIL UNIT Page 20 TAIL UNIT REMOVAL Page 21 UNDER TAIL ASSEMBLY Page 24 DISASSEMBLING UNDER TALE UNIT Page 25 ...

Page 111: ...C Bodywork 3 FAIRING ASSEMBLY ...

Page 112: ...G FRONT HEADLAMP Disassemble the two fixing screws of the headlamp Release the headlamp from the support for the lumi nous beam height control Disconnect the electric connection 1 and remove the headlamp 4 Bodywork C ...

Page 113: ...NTATION PANEL Unscrew the fixing screws and remove the instrumen tation panel cover by acting in the shown direction Release the connector 1 Unscrew the fixing screw of the instrumentation panel and withdraw it from the support 5 C 1 ...

Page 114: ...u should prelimi narily carry out the disassembling of the front headlight and the instrumentation panel as described in the pre vious pages Disconnect the connectors Withdraw the wiring from the headlight support hooks Disconnect the warning horn 6 Bodywork C ...

Page 115: ...nscrew the three fixing screws and remove the sup port For reassembling perform the following operations Apply the breakthread Loctite 243 on the threaded part of the three fixing screws Position the headlight support under the steering base and insert the three fixing screws with the washers without tightening Push lightly the headlight support towards the back part of the motorcycle until the sc...

Page 116: ... 8 Bodywork C FUEL TANK ...

Page 117: ...emove the ignition commutator protection by unscrewing the two fixing screws 1 DISASSEMBLING FUEL TANK SIDE PANELS Operate on the left side of the motorcycle Release the trailing part of the left side panel by relea sing the peg A from its seat B on the rubbered sup port fastened in the rear part of the tank making it accomplish the movement shown in the figure 9 C B A ...

Page 118: ...in order to release it from the special rub bered screw 1 fastened to the fuel tank Make the same operations in order to remove the right side panel FUEL TANK REMOVAL Unscrew and remove the special rear fixing screw 1 of the fuel tank to the rear sub frame 10 Bodywork C 1 ...

Page 119: ...nscrew and remove the special rubbered screw 1 on the tank support 1 Unscrew and remove the two support fixing screws 1 of the tank support Make the same operations on the left side of the motorcycle in order to remove the tank support 11 C ...

Page 120: ... support and the other on the rapid unions release Release the rapid unions 1 Pay attention to any fuel leakages put a rag in order to protect the underlying parts The release of the fuel tubing occurs when you press the held seat on the union as you can see in the figure In case of replacement of the rapid clutch terminals indicated in the figure apply Loctite 577 on the threaded part respecting ...

Page 121: ...or of the fuel flange pump 1 of the main wiring 1 Withdraw the fuel breather pipe 1 connected to the three way union Removing of the fuel tank plug Insert the motorcycle key in the fuel plug lock rotate clockwise and open the plug 13 C ...

Page 122: ... make the same operations in the opposite direction in regard to disassembling ones by tightening them at the descri bed torque and apply the indicated brakethread Fuel filler cap fixing screws torque pressure External screws 5 7 N m Fuel tank plug Apply Loctite 243 and screw in lightly 14 Bodywork C 5 7 N m ...

Page 123: ...Bodywork 15 C AIR FILTER COMPARTMENT ...

Page 124: ...ment you should primarily remove the fuel tank as described in the para graph Tank of this chapter Unscrew and remove the fixing nut 1 of the earth wiring of the gearcase Disconnect the connector 1 of the temperature sen sor and the air pressure from the sensor 16 Bodywork C ...

Page 125: ...ection to the gearcase from the main wiring 1 1 Release the fixing springs 1 of the air filter compart ment box to the throttle body 1 Unscrew and remove the two side fixing screws 1 of the air filter compartment to the frame 17 C ...

Page 126: ...isconnect the breather piping 1 from the block Unscrew and remove the two fixing screws 1 and the air filter compartment locking support 2 Remove the air filter compartment from the throttle body 18 Bodywork C ...

Page 127: ...ench Torque wrench of the air filter compartment fixing screws and locking support 8 10 N m Apply Loctite 243 If you had to remove the fixing screws of the throttle body springs 1 during their reassembling apply the described brakethread and tighten them to the indica ted torque Torque wrench of the fixing screws of the throttle body fly springs 5 7 N m Apply Loctite 243 8 10 N m 5 7 N m ...

Page 128: ... 20 Bodywork C TAIL UNIT ...

Page 129: ...ening seat lock on the left side of the motorcycle and rotate it clockwise In the meantime push lightly on the passenger seat The lock will be released Remove the passenger seat Release the fixing clip of the rider seat and remove it from its seat by lifting it 21 C ...

Page 130: ...e the three fixing screws 1 of the tale unit panels on both sides paying attention to reco ver the nylon washers 2 After that remove the side panels Extract the lamp holder of stop and side light from its seat 22 Bodywork C 1 2 ...

Page 131: ...work Unscrew the four fixing screws of the rear part tale unit Remove the rear part of the tale unit Release the electric connector and remove the lamp holder of the tail and stop light with the wiring 23 C ...

Page 132: ... 24 Bodywork C UNDER TAIL ASSEMBLY ...

Page 133: ...eats and the side panels as described in the previous paragraph Disassembling tale unit Disconnect the connections of the direction indicator and of the number plate light Unscrew the three fixing screws of the number plate holder Remove completely the number plate holder 25 C ...

Page 134: ...Unscrew the fixing screws of the battery connections and remove it from its seat Release the connector from the solenoid starter Remove the fixing screw of the starter 26 Bodywork C ...

Page 135: ...Bodywork Unscrew the under tale unit fixing screws Remove the under tale unit 27 C ...

Page 136: ... 28 Bodywork C ...

Page 137: ...Air intake injection system 1 D SECTION D Revision 0 ...

Page 138: ...ION TIME COMPENSATION PAGE 4 INJECTION ARREST CONTROL PAGE 4 MOTOR CONTROL POSITION OF THE PARTS PAGE 6 FUEL PUMP CONTROL SYSTEM PAGE 7 COMPONENTS PAGE 9 SENSORS PAGE 11 ENGINE PICK UP PAGE 14 TIMING WHEEL GAP PAGE 14 ACTUATORS PAGE 15 DIAGNOSTICS SYSTEM PAGE 16 INJECTION SYSTEM ELECTRICAL DIAGRAM PAGE 17 2 Air intake injection system D ...

Page 139: ... control is of a semi sequential type that is to say the four injectors are controlled in couples accor ding to the intake sequence The ignition is of the static inductive charge type with control of coil charge time integrated into the power modules inside the CPU INJECTION SYSTEM TECHNICAL CHARACTERISTICS INJECTION TIME INJECTION VOLUME The factors for the determination of the injection time are...

Page 140: ...s along the intake con duits AIR INTAKE TEMPERATURE SENSOR SIGNAL When the temperature of the intake air is low the injection time volume is increased to compensate the higher presence of oxygen BATTERY VOLTAGE SIGNAL The battery voltage signal is supplied to the ECU for the functioning of the ECU and this voltage is revea led and utilised as a signal for the compensation of the injection time vol...

Page 141: ...rds to the position of the switches of the side stand and the gearchange The ignition timing is precisely controlled with regards to the engine r p m and the position of the accelera tor Other than this basic condition also the temperature intake air pressure and the temperature of the engine coolant influence the ignition timing N B The ignition interruption circuit is incorporated in the ECU to ...

Page 142: ... Pompa carburante G Sensore posizione acceleratore H Iniettori carburante I Centralina servizi L Centralina di controllo motore M Teleruttore avviamento A Instrument panel B Engine coolant temperature sensor C Ignition coil D Camshaft position sensor E Intake air pressure tempera ture sensor F Fuel pump G Accelerator position sensor H Fuel injectors I Service unit L Motor control unit M Starter sw...

Page 143: ... shaft during or after the three seconds the motor rotation signal is sent to the CPU that by controlling the pump relay makes the pump motor function continuously When the ignition switch is switched to the OFF position the control of the pump relay is interrupted and contemporaneously also the control of the injectors and the ignition coils thereby causing the engine to switch off IGNITION CONTR...

Page 144: ...e motor The fuel is injected into the air intake conduit when the injector opens following a law generated by the ECU The excess fuel is not consumed and returns to the tank via return fuel tube SCARICO CARBURANTE A TERRA TROPPO PIENO SCARICO ACQUA A TERRA POMPA CARBURANTE FILTRO CARBURANTE TUBO MANDATA CARBURANTE RACCORDO BIANCO TUBO RITORNO CARBURANTE RACCORDO NERO SCARICO ACQUA E CARBURANTE A T...

Page 145: ...of an electric motor of the rotor impeller con trol valve and pressure release valve The ECU controls the ON OFF condition as described in the section FUEL PUMP CONTROL SYSTEM When electrical energy is supplied to the pump the motor switches on and the impeller activates This causes a difference in pressure on both sides of the impeller because the paddles of the impeller are grooved The fuel is t...

Page 146: ... of a diaphragm spring and valve It always maintains the pressure of the fuel sent to the injector at 3 0 kg cm2 300 kPa When the pressure of the fuel rises above 3 0 kg cm2 300 kPa the excess fuel opens the valve of the regulator and therefore can return to the fuel tank 10 Air intake injection system D ...

Page 147: ...emperature Intake air pressure sensor The sensor reveals the pressure of the intake air and this pressure is therefore converted into voltage that is sent to the ECU The basic injection time volume of the fuel is determined according to the voltage of the signal output voltage The voltage increases when the pressure of the intake air is high 11 D Pressure of the intake air mmHg Output voltage V Lo...

Page 148: ...take air temperature is low The resistance of the Thermistor increases when the air temperature is low and diminishes when the temperatu re is high NTC type sensor A B C D AIR TEMPERATURE D C Air temperature sensor characteristics Temperature C Resistance kΩ 10 9 5 0 6 10 3 8 20 2 5 30 1 6 40 1 1 60 0 6 AIR PRESSURE D A VOLTAGE FEED TEST D B 4 9 0 1 volt 12 Air intake injection system D Low High H...

Page 149: ...the accelera tor 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 according to the output voltage of this sensor The voltage increases when the accelerator opening is increased RESISTANCE TEST A C FEED TEST 4 9 1 volt 13 D A pin 16 B 5V pin 14 C Signal pin ...

Page 150: ...ween the two points identified by and a that are indicated on the connector Pick up resistance value 680 700Ω TIMING WHEEL GAP To guarantee the correct functioning of the pick up it is necessary to measure the gap between the pick up and the timing wheel that is to say the distance between the pick up and the timing wheel by utilising a feeler gauge as shown in the figure GAP width 0 6 0 7 mm To c...

Page 151: ...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 valve is constant the volume of fuel injected at any one time is dependent on the time that the solenoid is agitated injection time TECHNICAL DATA Winding resistance 14 5 Ω Ignition coils The ignition coils are ...

Page 152: ...hich is capable of identifying and recording the faults present or that were present previously on the motorcycle This software is equipped with a guide book for the use of the software itself to carry out checks on each indivi dual component of the system the MDST software allows to carry out the following operations reading of engine parameters reading of faults and their deletion active diagnos...

Page 153: ...AM 17 D IGNITION CONTROL SAFETY SWITCH BATTERY NEUTRAL LED SWITCH CLUTCH SWITCH SOLENOID STARTER SIDE STAND SWITCH GEARCASE 1 8 W SPARK PLUG COVERS WITH SUPPRESSOR THROTTLE BODY PICK UP LATCH RELAY FUSE 13 FUSE 03 FUSE 09 FUSE 11 FUSE 15 GENERAL RELAY POWER RELAY ...

Page 154: ...eratue sensor signal analogue input 14 sensor reference voltage power output 15 K tx line comunication line 16 sensor gnd power output 17 power gnd power input 18 nc 19 cylinders 2 3 coil control power output 20 fan control 21 nc 22 injectors 1 4 control power output 23 power relay control fuel pump of coil injectors digital output 24 revcounter control frequency output 25 nc 26 on key input digit...

Page 155: ...Electrical system 1 E SECTION E Revision 0 ...

Page 156: ...OR CHECK PAGE 33 STARTER MOTOR ASSEMBLY PAGE 33 IGNITION SIDE STAND SAFETY SYSTEM PARTS CHECK PAGE 35 GEARCHANGE POSITION SWITCH PAGE 36 SIDE STAND SWITCH PAGE 36 SPARK PLUGS PAGE 37 INSTRUMENTATION PAGE 40 OIL PRESSURE SENSOR PAGE 41 FUEL LEVEL WARNING LIGHT CHECK SWITCH PAGE 41 INSTRUMENT PANEL WATER SENSOR PAGE 42 KEY IGNITION SWITCH PAGE 42 STARTER RELAY ACTIVATION PAGE 42 LEFT DIRECTION INDIC...

Page 157: ...sconnecting 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 not corroded or dirty FUSES When a fuse burns out always investigate why the fuse has burnt out Find the cause repair and then substitute the fuse Do not utilise a fuse of a different capacity from ...

Page 158: ...tion to not drop parts incorporating semiconductors ECU instrument panel CPU When checking these components carry out the instruction strictly The lack of using the correct pro cedure can cause grave damage 4 Electrical system E INCORRECT ...

Page 159: ...Electrical system 5 E ELECTRICAL DIAGRAM ...

Page 160: ...n ted out E g Br Bk Iniettori Parts list Ref Description 32 Instrument panel 33 Air temperature pressure sensor 34 Left indicator 35 Horn 36 Water temperature sensor for instrument ther mometer 37 Light switch 38 Frame CPU earth 39 Battery recharge 40 Clutch switch 41 Starter motor 42 Frame earth 43 Engine earth Parts list Ref Description 1 CPU 2 Number plate light 3 Right indicator 4 Left indicat...

Page 161: ...vated INITIAL BATTERY CHARGE Proceed with charging following the method on the packet that the battery came in or as indicated in the following table Charging method It is preferable to charge the battery at a constant vol tage to not overcharge battery as follows 7 E BATTERY ASSEMBLY Insert the motorcycle key into the rear lock Turn the key clockwise while lifting the passenger seat up ...

Page 162: ... 8 Electrical system E Lift up the rider seat and remove it Remove the passenger seat as shown in the figure Rotate the rider seat fastener as shown in the figure ...

Page 163: ...cycle Battery terminal assembly Assemble the two positive terminal leads on the relative battery pole respecting the order shown in the figure Pay attention to the colours of the cable in order to position them correctly Rotate the screw of positive terminal leads and tighten to the prescribed torque using a torque wrench Torque pressure 7 8 N m 7 8 N m ...

Page 164: ...e wrench Torque pressure 7 8 N m Before tightening make sure that the cables are oriented correctly 7 8 N m When the terminals are mounted replace the protec tion cover on the positive pole see figure Connect the two negative terminal leads to the rela tive pole of the battery respecting the placing shown in the figure ...

Page 165: ...IA POLO NEGATIVO CAVO POSITIVO ATTENZIONE Alla fine dell ope razione di montaggio assicurar si che il cavo del terminale posi tivo sia posizionato all interno della struttura del telaietto poste riore vedi figura PLACEMENT AND ASSEMBLY OF TERMINALS WIRE TERMINALS ON THE BATTERY NEGATIVE WIRE POSITIVE WIRE CAUTION Before tightening ensure that the wires are correctly oriented see the figure NEGATIV...

Page 166: ...e characteristics of the regulator with steps of variation of the regulated voltage Stator coil Ignition Switch B IG S S Tr3 L L R Charge Lamp M IC IC Regulator F P Tr1 F B IG E Rotor coil Battery Load CHARGING SYSTEM The system of the charging circuit illustrated as follows is substantially composed of a generator and a rectifier regulator enclosed in one component The alternating current AC is t...

Page 167: ...the generator is not functioning and does not generate any voltage The voltage at point P is 0V and M IC revealing this value activates Tr3 which switches on the warning light Stator coil Ignition Switch B IG S S Tr3 L L R Charge Lamp M IC IC Regulator F P Tr1 F B IG E Rotor coil Battery Load In the preceding diagram is illustrated the complete charging circuit The input circuit of the regulator i...

Page 168: ...low of current and a rapid recharge At this point the M IC disactivates also Tr3 that switches off the warning light When the voltage at terminal B exceeds the battery voltage then the battery starts recharging R Stator coil Ignition Switch B IG S S Tr3 L L Charge Lamp M IC IC Regulator F P Tr1 F B IG E Rotor coil Battery Load 2 Recharging voltage less than the regulated voltage ...

Page 169: ...tage approximately 14 5V at 25 the I MC realises it and puts the Tr1 in the OFF position This condition is maintained until the voltage at terminal S does not become less than the regulated voltage R Stator coil Ignition Switch B IG S S Tr3 L L Charge Lamp M IC IC Regulator F P Tr1 F B IG E Rotor coil Battery Load Charge Current 3 Recharge voltage more than the regulated voltage ...

Page 170: ... interrupts the current and the vol tage at terminal P goes to zero The M IC reveals this condition and through the Tr3 switches on the warning light Stator coil Ignition Switch B IG S S Tr3 L L R Charge Lamp M IC IC Regulator F P Tr1 F B IG E Rotor coil Battery Load Charge Current 4 Rotor coil disconnected ...

Page 171: ... through Tr3 switches on the warning light At this point the M IC to maintain the voltage at terminal B between 13 3V and 16 3V activates and disactivates Tr1 R Stator coil Ignition Switch B IG S S Tr3 L L Charge Lamp M IC IC Regulator F P Tr1 F B IG E Rotor coil Battery Load Charge Current 5 Disconnection of terminal S of the regulator ...

Page 172: ...M IC maintains the voltage at ter minal B at 20V protecting the alternator and the rectifier in the moment in which the voltage at terminal S drops under 13V The M IC reveals it through Tr3 and activates the warning light Stator coil Ignition Switch B IG S S Tr3 L L R Charge Lamp M IC IC Regulator F P Tr1 F B IG E Rotor coil Battery Load Charge Current Connettore a 4 vie 4 1 2 6 Terminal B disconn...

Page 173: ...minal L and earth Repair the fault Check that there is a good connection of the charging leads and the charging fuse Substitute the alternator NO NO YES With the engine switched on at approxi mately 2000 r p m check the voltage of the battery all utilities must be switched off and the regulator at 25 C the voltage must be 14 5V 0 6 N B At different temperatures the voltage can be between 13V and 1...

Page 174: ...n the negative ter minal and the negative cable of the battery Losses are indicated if the tester measures more than 2 2 5mA Battery current loss less than 1mA First of all when using an ampmeter utilise a high range of the multi tester because the current los ses in the case of malfunctioning could be eleva ted If losses are found search for the part where the tester measures less than 2 2 5mA by...

Page 175: ...ctor on main beam Hl Measure the voltage between the positive and negative terminals of the battery with a multi tester If the tester indicates less than 12 6V or more than 14 3V the cause will be found in the generator When carrying out this check ensure that the battery is fully charged Standard recharge voltage 12 6 14 3V at 2000 r p m N B Battery Tester VCC ...

Page 176: ...ht is reduced FUNCTION DIAGRAM BAT ON OFF RIGHT CONTROL CLUTCH SWITCH ENGINE CONTROL GERCASE PIN 7 CLUTCH SWITCH STAND SWITCH NEUTRAL SWITCH IGNITION SWITCH FUEL INJECTOR COIL PUMP ENGINE CONTROL GEARCASE PIN 23 DIRECT POSITIVE FOR INSTRUMENT PANEL ALTERNATOR TAIL LIGHTS RIGHT CONTROL KLAXON POSITIVE 02 STOP LIGHTS POSITIVE 04 INTERMITTENCE LED RIGHT IND CONTROL LEFT IND CONTROL RIGHT TURN INDICAT...

Page 177: ... I NO NO 2 I O I NO NO 3 I I O NO NO 4 I O O NO NO 5 O O I NO NO 6 O I I SI SI 7 O I O SI SI 8 O O O SI NO GEAR I neutral condition O not neutral condition STAND I down O up CLUTCH LEVER I pulled lever O leaved lever Start switch disabled ENGINE LOCKED OFF Engine forced off IN EFFECT ELECTRIC START LOCKED DISABLED STARTER SYSTEM The diagram below represents the starter system IGNITION INJECTION SY...

Page 178: ...n IGNITION CONTROL SAFETY SWITCH BATTERY NEUTRAL LED SWITCH CLUTCH SWITCH SOLENOID STARTER SIDE STAND SWITCH GEARCASE 1 8 W SPARK PLUG COVERS WITH SUPPRESSOR THROTTLE BODY PICK UP LATCH RELAY FUSE 13 FUSE 03 FUSE 09 FUSE 11 FUSE 15 GENERAL RELAY POWER RELAY ...

Page 179: ...owered Gear engaged Clutch not pulled in Engine not switched on IGNITION CONTROL SAFETY SWITCH BATTERY NEUTRAL LED SWITCH CLUTCH SWITCH SOLENOID STARTER SIDE STAND SWITCH GEARCASE 1 8 W SPARK PLUG COVERS WITH SUPPRESSOR THROTTLE BODY PICK UP LATCH RELAY FUSE 13 FUSE 03 FUSE 09 FUSE 11 FUSE 15 GENERAL RELAY POWER RELAY ...

Page 180: ... the OFF Position IGNITION CONTROL SAFETY SWITCH BATTERY NEUTRAL LED SWITCH CLUTCH SWITCH SOLENOID STARTER SIDE STAND SWITCH GEARCASE 1 8 W SPARK PLUG COVERS WITH SUPPRESSOR THROTTLE BODY PICK UP LATCH RELAY FUSE 13 FUSE 03 FUSE 09 FUSE 11 FUSE 15 GENERAL RELAY POWER RELAY ...

Page 181: ...lowered Gear engaged Clutch not pulled in Engine not switched on IGNITION CONTROL SAFETY SWITCH BATTERY NEUTRAL LED SWITCH CLUTCH SWITCH SOLENOID STARTER SIDE STAND SWITCH GEARCASE 1 8 W SPARK PLUG COVERS WITH SUPPRESSOR THROTTLE BODY PICK UP LATCH RELAY FUSE 13 FUSE 03 FUSE 09 FUSE 11 FUSE 15 GENERAL RELAY POWER RELAY ...

Page 182: ...and raised Gear engaged Clutch released Engine switched on IGNITION CONTROL SAFETY SWITCH BATTERY NEUTRAL LED SWITCH CLUTCH SWITCH SOLENOID STARTER SIDE STAND SWITCH GEARCASE 1 8 W SPARK PLUG COVERS WITH SUPPRESSOR THROTTLE BODY PICK UP LATCH RELAY FUSE 13 FUSE 03 FUSE 09 FUSE 11 FUSE 15 GENERAL RELAY POWER RELAY ...

Page 183: ...nd raised Gear engaged Clutch pulled in Engine switches on IGNITION CONTROL SAFETY SWITCH BATTERY NEUTRAL LED SWITCH CLUTCH SWITCH SOLENOID STARTER SIDE STAND SWITCH GEARCASE 1 8 W SPARK PLUG COVERS WITH SUPPRESSOR THROTTLE BODY PICK UP LATCH RELAY FUSE 13 FUSE 03 FUSE 09 FUSE 11 FUSE 15 GENERAL RELAY POWER RELAY ...

Page 184: ...lowered Gear engaged Clutch pulled in Engine does not switch on IGNITION CONTROL SAFETY SWITCH BATTERY NEUTRAL LED SWITCH CLUTCH SWITCH SOLENOID STARTER SIDE STAND SWITCH GEARCASE 1 8 W SPARK PLUG COVERS WITH SUPPRESSOR THROTTLE BODY PICK UP LATCH RELAY FUSE 13 FUSE 03 FUSE 09 FUSE 11 FUSE 15 GENERAL RELAY POWER RELAY ...

Page 185: ...owered Gear not engaged Clutch not pulled in Engine switched on IGNITION CONTROL SAFETY SWITCH BATTERY NEUTRAL LED SWITCH CLUTCH SWITCH SOLENOID STARTER SIDE STAND SWITCH GEARCASE 1 8 W SPARK PLUG COVERS WITH SUPPRESSOR THROTTLE BODY PICK UP LATCH RELAY FUSE 13 FUSE 03 FUSE 09 FUSE 11 FUSE 15 GENERAL RELAY POWER RELAY ...

Page 186: ...Remove the conduit of the cylinder cooling system Disconnect the cable of the starter motor Remove the two fixing screws of the starter motor Remove the starter motor by extracting it as indica ted in the figure Substitute the burnt fuse and replace the cover find the electrical fault before replacing the fuse To identify the position and the function of the fuses consult the information written o...

Page 187: ...positive pole and the engine earth If there is no continuity substitute the starter motor STARTER MOTOR ASSEMBLY Assemble the starter motor in the reverse order of removal Pay attention to the following points Substitute the O ring with a new one to avoid oil leakage and the ingress of humidity Apply grease to the oil seal lip Apply a small quantity of MOLYKOTE to the rotor shaft Apply a small qua...

Page 188: ...ct the cables of the starter motor and the positive cable of the battery from the relay Starter relay check Remove the rider seat disconnect the battery Unhook the connector from the starter relay Unscrew the fixing screw of the relay ...

Page 189: ...he relay and check the continuity between terminals B M Do not apply the battery voltage to the starter relay for more than five seconds to avoid overheating and therefore damaging the winding Using a multi tester check that the winding is on open circuit or if a resistance is present The winding is in good condition if the value of the resistance revealed is as indicated Starter relay resistance ...

Page 190: ...eck the continuity between the black lead and earth with the gears in neutral When the connector of the gearchange posi tion switch is connected and disconnected be sure to turn the ignition switch to the OFF position to avoid damaging the elec tronic parts SIDE STAND SWITCH The connector for the lateral stand switch is mounted on a support under the pinion wheel transmission casing on the left si...

Page 191: ...t Left side panel Right side panel Fuel tank Air filter compartment Remove the coil connectors To carry out this operation free the secondary lock yellow tongue removing it from its seat then press the black tongue and unhook the connector Unscrew the earth connection from the cylinder head cover and free the coil wiring from the frame removing the two fixing band fasteners then slide the wiring o...

Page 192: ...ctor correctly If not connected or if connected incorrectly it could cause damages to the coils themselves Check the resistance between the electrode and the screw cap of the spark plug as shown in the figure Permitted resistance 4 5 5 5 K Carry out the test on all the spark plugs RUN OFF SAFETY SWITCH Remove the instrument panel cover unscrewing the two fixing screws on the sides ...

Page 193: ...stem 39 E Remove the relative connector to the right hand control group as indicated in the figure Remove the plug part of the connector With the switch in the RUN position check the conti nuity between pins 1 and 2 ...

Page 194: ...ks remove the instrument panel cover then move aside the rubber cap and the connector situated behind the instrumentation Consult the diagram below to identify the contacts of the various components 1 Side stand 11 Starter relay output 2 Oil press 12 Engine starter switch 3 High beam 13 Turn L 4 Lights 14 Turn R 5 Neutral 15 Open 6 Low fuel 16 Ta pulse 7 CHG 17 Open 8 Temp sensor 18 Sp pulse 9 IGN...

Page 195: ...orcy cle the good condition of the relative fuse Having ascertained the good condition of the fuses in question proceed as follows With the fuel tank removed from the motorcycle and empty of fuel connect a small circuit composed of 12V battery and a light bulb of 12V 1 7W to the connector of the fuel level indicator as shown in the diagram If the switch is in a good condition the light bulb should...

Page 196: ...se can be identified by a fault in fuses 13 or 3 If the fuses are in good condition check the continuity between the pin 9 of the instrument panel and the pin 15 of the fuse box connector and between the pin 10 of the instrument panel and the pin 12 of the fuse box connector STARTER RELAY ACTIVATION Check that there is a 12V input between pin 11 and 20 with the safety switch in the RUN position an...

Page 197: ...pin 14 and pin 20 If the presence of input voltage is verified the conti nuity between pin 14 of the instrument panel and pin 7 of the right hand control connector must be checked RPM INDICATOR If the r p m of the engine is not signalled on the instru ment panel with the engine switched on check The continuity between pin 16 of the instrument panel and pin 20 of the CPU If the cause is verified th...

Page 198: ... fuse 7 If the fuse is in good condition check the cooling fan relay mounted on the right side of the motorcycle as indicated in page 38 If the relay is in good condition but does not become excited disconnect the connector of the temperature sensor marked by an M on the lead Make a bridge between the two contacts as shown in the figure With the ignition switch in the ON position the fan should op...

Page 199: ...fuse 11 in the fuse box on the right side of the motorcycle If the fuse is in good condition disconnect the con nector of the left control and check the continuity between contact 34 of the control with the klaxon but ton pressed as in the following page under Switches Check the continuity of the winding of the klaxon ...

Page 200: ... 46 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 ...

Page 201: ... 1 F Suspension and wheels SECTION F Revision 0 ...

Page 202: ...RK PAGE 10 FRONT FORK OVERHAUL PAGE 11 STEERING ASSEMBLY PAGE 23 STEERING ASSEMBLY OVERHAUL PAGE 24 REAR SUSPENSION AND FORK PAGE 29 MONO ARM FORK REMOVAL AND OVERHAUL PAGE 36 REAR WHEEL HUB PAGE 44 REAR WHEEL REMOVAL PAGE 45 MOTORCYCLE SET UP ADJUSTMENT PAGE 58 WHEEL BALANCE CHECK PAGE 62 ...

Page 203: ... 17 FRONT TYRE Dimensions 120 65 ZR 17 56 W Brand and type PIRELLI Dragon Evo MTR21 Corsa PIRELLI Diablo Corsa DUNLOP Sport Max D 207 MICHELIN Pilot Sport Race Replica MICHELIN Pilot Power DUNLOP Sport Max D 207 Race Replica Front tyre pressure 2 3 bar 33 psi 2 3 bar 33 psi When using tyres of a brand which is different from the recommended type refer to the tyre pressure marked by the manufac tur...

Page 204: ...emoved calipers so that they do not hamper subsequent operations Protect the disassembled calipers with pro tective material thereby avoiding possible damage to the wheel rim Hold the calipers appropriately to not charge the brake tubes Pay attention to not bend the brake tubes to avoid any damages Lift the motorcycle up at the front end Mount the special tool that is supplied with a pin on the lo...

Page 205: ...the wheel spindle still mounted to the wheel rota te the wheel to check that the bearings are not pitted and rotate with a smooth action Check also for axial A and or radial B movement If either condition is verified substitute the bearings Front wheel bearing substitution Remove the wheel spindle utilising the special tool as shown in the figure Special tool N 800092872 F 5 ...

Page 206: ...ted above it is advisable to remove the brake discs as indicated in chapter Brakes to avoid damaging them Special tool N 800092862 Introduce the extractor until the internal ring of the bea ring is hooked up Introduce the wheel spindle and screw and manually block them Mount the flange spacer ring and nut utilising a 14 mm spanner and a 27 mm spanner and extract the bearing as shown in the figure ...

Page 207: ... not scored or marked Reassembly front wheel bearings Before proceeding with the reassembly accurately clean the bearing seats in the wheel hub Mount a bearing onto the special tool Special tool N 800092868 Introduce the stem of the tool into the wheel hub as shown in the figure and insert the aluminium spacer F 7 ...

Page 208: ...lustrated 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 completed the assembly check that the alumi nium spacer does not have axial play Assemble the wheel spindle and carry out again the rolling check by rotating the wheel F 8 ...

Page 209: ...he 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 the left side of the motorcycle Screw ring of the frontal wheel spindle Torque pressure 40 44 N m Special tool N 800092872 1 Mount the wheel complete with wheel spindle onto the wheel attachments of the front forks Ensure that the attachments do not sit on...

Page 210: ... telescopic forks with the stems positioned upside down equipped with a system of external adjustment for extension compression and spring preload Ø stems mm 50 with Titanium Nitride treatment 50 Telescopic movement 128 128 A B C D E F G H I L M N O N m 40 20 20 20 8 10 8 9 16 18 22 24 20 22 Kg m ft lb Torque pressure Operation FRONT FORK ...

Page 211: ...he screw 1 of the steering head and the three screws 2 of the steering base During this phase support the stem Slide out the stem supporting it with both hands and operating with caution so as not to drop it Proceed with the same operation for both stems Fork overhaul Place the stem in a vice paying attention to protect the surfaces to not damage them F 11 ...

Page 212: ...rew the cap and lower the sleeve as shown in the figure This operation must be carried out keeping the stem in a vertical position Unscrew the cap Using the key adjust the spring pre load adjuster while blocking the rotation of the nut pla ced on the pump rod F 12 ...

Page 213: ...Suspension and wheels 1 Remove the spring push spacer 1 and the relative spacer ring Slide out the spring complete with the spacer Remove the internal rod for adjusting the extension F 13 ...

Page 214: ...an appropriate container Do not dispose of the used oil in the envi ronment Unscrew the lower central screw that fixes the pump unit Collect the seal washer underneath When reassembling tighten to 40 N m Extract the pump unit Check that the sealing ring on the pump is still in its seat only for MY04 and successive F 14 40 N m ...

Page 215: ...ower the anti dust seal 1 taking care to not damage the seat on the sleeve 1 Remove the retaining ring 1 with a screwdriver taking care to not scratch the stem Extract the sleeve from the stem by repeated blows at the end F 15 ...

Page 216: ...side the assembly Ensure that the inside is completely smooth without any scratches If necessary substitute with a new part Check for marks or scratches on all surfaces of the stem and check the condition of the chroming Check the length of the spring 265 mm mini mum Manually widen the upper bush and extract it Remove the lower bush the washer the oil seal and the anti dust seal see figure F 16 ...

Page 217: ... 2 and the anti dust seal 1 from any sharp edges on the lips of the stem during assembly Recommended grease MOLYKOTE 55M Visually check for scratches and marks on the pump rod and check that it slides smoothly inside the pump unit without chamfering Substitute if necessary Assemble the stem into the sleeve placing the ferrules into their seats with the respective washers Utilise the special tool U...

Page 218: ...pression hydrau lic brake adjuster 20 N m Insert the internal rod Maintain the sleeve in a vertical position Introduce the following amount of oil BRUTALE ORO S MY 03 646 cc BRUTALE S MY 04 655 cc Press the pump rod up and down until a perfect fluidity of movement is obtained Recommended oil BRUTALE ORO S MY 03 SAE 5 BRUTALE S MY 04 SAE 7 5 F 18 20 N m ...

Page 219: ... 03 X 110 mm BRUTALE S MY 04 X 105 mm Manually screw in the locknut until it reaches the end of the thread then introduce the spring with the spacer The locknut has a special assembly direc tion Pay attention to keep the two support bases facing upwards see the figure below 1 Insert the key on the pump nut 1 slightly pressing down the spring F 19 ...

Page 220: ...h is reported below BRUTALE ORO S MY 03 04 X 165 mm Suspension and wheels 1 Place the spring push spacer 1 and the relative washer Reassemble the complete cap with a new O ring Tighten the cap to the prescribed torque pressure Stem cap torque pressure 20 N m Reassemble the cap on the stem tightening it to the prescribed torque pressure Stem cap torque pressure 20 N m F 20 20 N m 20 N m ...

Page 221: ...e pressure is reached This operation must be carried for both stems Torque pressure of the screws at the base of the steering 8 9 N m F 21 8 9 N m 3 2 Slacken the central screw 3 of the steering head Ensure that the steering head is sitting perfectly in its seat Tighten the two screws 2 of the steering head to the prescribed torque pressure and successively tighten the central screw 3 Torque press...

Page 222: ...sary that the adjusters on both fork stems are adjusted to the same posi tion F 22 Type of set up Brutale S MY 03 Soft Standard Hard Spring preload 2 turns 4 turns 6 turns Braking in extension 13 clicks 10 clicks 7 clicks Braking under compression 11 clicks 8 clicks 5 clicks Type of set up Brutale ORO Soft Standard Hard Spring preload 0 turns 2 turns 4 turns Braking in extension 13 clicks 10 click...

Page 223: ...Suspension and wheels F 23 E C D D B A STEERING ASSEMBLY A B C D E N m 95 100 18 20 In contact 10 Kg m ft lb Torque pressu re Operation 270 ...

Page 224: ...nt headlight instrument panel handlebars headlight support as described in chapter C Bodywork 1 Steering head removal Slacken the fixing screw 1 of the steering head and remove it from the steering pin Steering base removal Utilising the special tool slacken the screw ring of the steering pin Support the motorcycle sufficiently enough so that the front stand can be removed Ensure that the brake pi...

Page 225: ...emoval With the special tool remove the fixing screw ring of the eccentric steering head Special tool N 800092857 During this operation press the tool with the palm of the hand along the axis of rotation and at the same time support the motorcycle Disassembly of the frame head steering sleeve Remove the adjustment screw of the frame head stee ring sleeve sustaining the frame head steering sleeve a...

Page 226: ...Agip Grease 30 Accurately clean the bearing seats on the frame head steering sleeve Recommended grease Agip Grease 30 1 Reassemble the frame head steering sleeve aligning the slot on the frame head steering sleeve with the threaded hole on the frame head see figure When the slot is in correspondence with the threaded hole of the frame head screw in the grub screw 1 without tightening Just enough t...

Page 227: ... pressure Special tool N 800092857 Torque pressure of the frame head steering sleeve screw ring 95 100 N m During this tightening operation press down with force along the axis of rotation of the tool see figure Tighten the grub screw 2 of steering head Torque pressure of the grab screw of the steering head 18 20 N m Assembly steering base Accurately clean all the parts and check the general condi...

Page 228: ... done manually Ensure that the steering base is at the end of stroke completely steered to the right Utilising the special tool tighten the screw ring 1 by rotating it 10 see figure calculable as one third distance between the two holes of the steering head screw ring 2 Special tool N 800091645 Assembly steering head Position the steering head in its seat Reposition the fork stems as described pre...

Page 229: ...ssion and spring preload Mono arm fork Magnesium alloy Aluminium alloy Wheel travel mm 120 120 During the disassembly and check of the rear suspension assembly it is advisable to disassemble the fuel tank as described in chapter C Bodywork A B C D E F G H I L N m 40 44 40 44 40 44 50 55 70 75 30 35 Kg m ft lb Torque pressure Operation 243 243 REAR SUSPENSION AND FORK ...

Page 230: ...dywork Lift up the rear part of the motorcycle utilising a lift and safety straps high enough to take the load off the shock absorber Slacken the upper screw of the shock absorber 1 1 Slacken the central screw 1 of the rear wheel com pensator assembly 1 Slacken the lower screw of the shock absorber 1 F 30 ...

Page 231: ...r 2 1 Slacken the central fixing pin of the engine 1 Slacken the rear fork pin 2 These operations are necessary to free the compen sator assembly Lift up the compensator assembly Remove the upper screw of the shock absorber that was previously slackened Extract the complete rear shock absorber upwards A B Rear shock absorber test Check that the lower and upper bolt holes do not have axial A and ra...

Page 232: ...d Braking in extension 8 clicks 8 clicksi 8 clicks Braking under compression 18 clicks 18 clicks 18 clicks high speed Braking under compression 12 clicks 12 clicks 12 clicks low speed BRUTALE S MY 04 F Type of set up only rider Soft Standard Hard Braking in extension 21 clicks 17 clicks 13 clicks Braking under compression 0 clicks 6 clicks 12 clicks high speed Braking under compression 18 clicks 1...

Page 233: ...ary to substitute them utilise an extractor as shown in the figure 2 Check for eventual axial play of the bolt holes of the connecting rod 2 Substitute if worn F 33 1 Compensator assembly removal Remove the special screw 1 that fixes the compen sator assembly of the rear suspension to the mono arm fork Extract the complete compensator assembly ...

Page 234: ... prescribed torque pressure Special product Loctite 243 Torque pressure 40 44 N m 1 Upper chain guide removal Remove the two screws 1 and the relative plates Lift up the front part of the chain guide to remove it from the mono arm fork see figure F 34 40 44 N m 1 2 Rear shock absorber support plate removal Remove the three screws 1 indicated in the figure and remove the support plate 2 ...

Page 235: ...ning of the front reference peg Reassembly compensator assembly Reassemble the compensator assembly after having cleaned and greased the seat of the special screw situated on the mono arm fork Screw in the screw without tightening it Recommended grease Agip Grease 30 F 35 Repeat the operation on the rear part where the screw seat is situated in the mono arm fork ...

Page 236: ...e following preliminary ope rations Remove the rear shock absorber and connecting rod as described in the paragraph Disassembly rear shock absorber e Compensator assembly removal of this chapter F 36 50 55 N m 55 60 N m 70 75 N m Assembly rear shock absorber Accurately clean all parts Grease the screws with Agip Grease 30 before reassembly Insert the shock absorber from above and lightly screw in ...

Page 237: ...al Unhook the two connecting springs between the silen cers and the exhaust group Remove the plate connecting the two silencers F 37 Rear wheel removal Remove the rear wheel as described in the paragraph Rear wheel removal of this chapter ...

Page 238: ...els Remove the upper silencer first then the lower one Exhaust group removal Unhook the two connecting springs between the silen cers and the exhaust collectors F 38 Unscrew the screw fixing the silencers to the support ...

Page 239: ...remove it from the pin on the left side of the frame 1 Lower chain guide removal Remove the three screws of the chain guide Remove the chain guide 1 complete with the two rear brake tube guide plates F 39 Unscrew the screw fixing the compensator to the frame ...

Page 240: ... tool has two functions As a chain cutter with a punch mounted aligned at A As an anvil with a raised punch aligned at B Pre assemble the tool as shown in the figure Align a pin with the central hole of the tool F 40 N B Upper chain guard removal Remove the screw complete with ferrule Extract the chain guard by pulling it out from the back part of the wheel see figure so that it is freed from its ...

Page 241: ...ned with B Utilise only new links Mono arm fork pin removal Remove the screw 1 on the right side of the motorcy cle Remove the washer and push out the pin manually Support the mono arm fork so that it does not drop to the ground F 41 B A Mount the tool onto the chain as shown in the figure and align the punch on A Operate as shown in the figure 1 ...

Page 242: ... F 42 Bearings overhaul If it is necessary to substitute the bearings of the mono arm because of excessive play operate as follows Remove the right and left spacer Remove the Seeger retaining ring on the right side of the mono arm Remove the anti dust seal on the left side Utilising the special tool remove the two roller bearing units Special tool N 800092860 LEFT SIDE Mount the tool so that both ...

Page 243: ...eat of the spacer If the spacer is in good condition reinsert it onto the fork from the right side Assembly of the roller bearings and the roller bea ring units Pre assemble the two roller bearing units on the left side and the two ball bearings on the right hand side utilising the special tool N 800092866 as shown in the figure Special tool N 800092866 ...

Page 244: ...0 x 17 6 00 x 17 REAR TYRE Dimensions 190 50 ZR 17 73 W o 180 55 ZR 17 73 W Brand and type PIRELLI Dragon Evo MTR 22 Corsa PIRELLI Diablo Corsa DUNLOP Sport Max D 207 MICHELIN Pilot Sport Race Replica MICHELIN Pilot Power DUNLOP Sport Max D 207 Race Replica Rear tyre 2 3 bar 33 psi 2 3 bar 33 psi pressure In the event of different make tyres being used as opposed to those advised refer to the pres...

Page 245: ...ecial tool N 800092642 Remove the fixing screws of the lower silencer Remove the exhaust protection Turn the lower silencer outwards slightly If this movement is difficult due to residues in the area of connection to the compensator clean the part applying lubricant WD 40 unblocking spray Rotate the silencer in a clockwise or anti clockwise direction alternatively to allow the lubricant to seep th...

Page 246: ...left hand thread To slacken the nut it is therefore necessary to turn the torque wrench in a clockwise direction Remove the rear wheel nut When reassembling tighten the rear wheel nut to the prescribed torque pressu re Rear wheel nut torque pressure 220 240 N m Remove the rear wheel taking care to not hit the silen cer connecting plate If this operation is too difficult to carry out remove the sil...

Page 247: ... the figure Remove the rear stand 1 Remove the safety ring 1 of the crown flange fixing nut Slacken the nut of the flange by rotating it in an anti clockwise direction as shown in the figure Utilise the following tools Torque wrench 55 mm polygonal spanner Remove the brake caliper as described in chapter H Brakes F 47 ...

Page 248: ...00092855 When adjusting the tension of the chain it is necessary to carry out the motorcycle set up adjustment See Motorcycle set up adjustment in this chapter 4 3 Crown wheel assembly removal Remove the wheel spindle nut 2 previously slacke ned and the spacer ring 4 underneath Remove the crown wheel assembly 3 by manually pulling the assembly outwards Make sure that a spacer ring is present betwe...

Page 249: ...g 2 the flange 3 and the spacer ring underneath Wheel hub disassembly Extract the wheel hub from the left side of the fork Carefully wash all parts Check the condition of the roller bearing and the ball bearing If there is excessive play even only one of the bea rings or chamferings during rotation substitute the wheel hub complete with bearings with a new unit If only one bearing is worn substitu...

Page 250: ... ORO Molykote BR2 PLUS Brutale S Caliper holder pin Unscrew the caliper holder pin only if it is damaged When reassembling apply the prescribed type of Loctite and tighten to the prescribed torque pressure Recommended 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 substit...

Page 251: ...e for wear A Utilising a press with an adequate punch for both the removal and assembly of the pins of the wheel drive engagement When assembling apply force on the crown of the peg not on the point see figure Assemble the brake disc carrier plate by tightening the screws to the prescribed torque pressure and then apply Loctite 270 Recommended thread locking fluid Loctite 270 Brake disc carrier pl...

Page 252: ...ng grease the area that comes into contact between the flange and the crown Do not apply grease to the threads of the pins Tighten the five nuts to 45 50 N m as shown in the figure Reassembly wheel hub Lightly grease the wheel hub Introduce the hub to the fork from the left side of the motorcycle and push it in Screw in the two screws on the fork without tightening Recommended grease Agip Grease 3...

Page 253: ...sure that the Seeger retaining ring is inserted around the whole circumference of the seat Introduce the first spacer Grease and insert the roller bearing unit Assemble the second spacer the ground one Recommended grease Agip GR SM If the recommended grease cannot be found it is possible to use a product having the following characteristics Lithium grease and molybdenum disulphi de NLGI consistenc...

Page 254: ...serted Mount the chain onto the crown wheel and adjust the eccentric adjuster until the chain is taught but not tight see the information printed on the chain adjustment nameplate Tighten the hub screws to the prescribed torque pres sure Do not go past this limit Exceeding the prescribed tightening torque may seriously damage the rear wheel hub and endanger the driver s safety Wheel hub screws tor...

Page 255: ...dicated in page 62 Insert 1st gear Reassemble the rear wheel Tighten the wheel axis nut to the prescribed torque pressure Rear wheel nut torque pressure 220 240 N m Insert the retaining ring Pinion wheel removal Remove the male connector holder 1 from the sup port plate fixed to the engine casing Remove the screw 1 of the clutch control cylinder and the three screws 2 of the pinion wheel cover 220...

Page 256: ...and hammer Unscrew the pinion wheel retaining nut Be careful to not hit the timing wheel situa ted on the extremity of the pinion shaft during this operation Slacken the chain see page 48 bring it forward and slide it off the pinion wheel Effectuate this operation only if the pinion wheel has to be substituted If the pinion wheel and crown wheel assembly have to be substituted it is advisable to o...

Page 257: ...ite faces of the hexagon Chain pinion wheel nut torque pressure 100 N m Recommended thread locking fluid Loctite 270 Reassemble the pinion wheel cover after having clea ned the support base Screw in the four screws lightly and proceed with the tightening screwing down respectively on the three screws M8 1 and on the screw M6 2 Replace the rubber bands and reinsert the electrical connector Coppia d...

Page 258: ...642 Insert the setting up arm A of the rear suspension special tool in its appropriate seats as shown in the figure Special tool N 800093347 Press down on the seat so that the shock absorber is compressed and then let it go back into its resting posi tion Measure the distance X1 between the upper extremity of the rear stand tube and the point on the setting up arm indicated by the arrow in the fig...

Page 259: ...If the static slack value is different from the indicated value it is necessary to effectuate the following adjust ment to the shock absorber spring Slacken the upper lock ring of the rear shock absorber rotating it in the direction indicated in the figure by uti lising a 75 mm key spanner Rotate the lower lock ring as shown in the figure either in a clockwise or anti clockwise direction according...

Page 260: ... the static set up quota X Press down on the seat so that the rear shock absor ber is compressed after which allow the motorcycle to return to its rest position Measure the distance X between the upper extremity of the rear stand and the point of the set up arm indi cated in the figure This distance represents the static set up quota of the motorcycle It should be equal to the following value BRUT...

Page 261: ... Continue the operation until the quota is equal to the following value BRUTALE ORO S MY 03 X 190 mm BRUTALE S MY 04 X 200 mm Tighten the fixing screws of the semi connecting rods to the prescribed torque pressure Torque pressure 8 10 N m After having completed the adjustment of the motorcy cle set up it is necessary to adjust the tension of the chain Check also the orientation of the front headli...

Page 262: ... 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 mark 1 present on the side of the tyre as shown in the figure It indicates the lighte st point of balancing and must be situated close to the tyre valve when the tyre is moun ted onto the wheel rim On the side Figure A Brutale S v...

Page 263: ...xed to the wheel Mount the wheel onto an adequate support similar to that shown in the figure utilising a ground pin of 35 mm diameter Check the wheel utilising a micrometer gauge and check the following tolerances Ovalization and maximum eccentricity must not exceed 0 5 mm Place the dial gauge as shown in the figure and check the flatness Flatness must not exceed 0 5 mm ...

Page 264: ...essary to refer to the yellow mark 1 present on the side of the tyre as shown in the figure It indicates the lighte st point of balancing and must be situated close to the tyre valve when the tyre is moun ted onto the wheel rim On the side Figure A Brutale S version Figure B Brutale Oro version N B ...

Page 265: ...Frame 1 G SECTION G Revision 0 ...

Page 266: ...MINARY OPERATIONS PAGE 3 THROTTLE BODY REMOVAL PAGE 7 FRAME DISASSEMBLY PAGE 12 FRAME CONTROL REFERENCE MEASUREMENTS PAGE 16 ASSEMBLY FRAME TO THE MOTORCYCLE PAGE 18 REAR SUB FRAME REMOVAL PAGE 22 ENGINE REMOVAL PAGE 25 2 Frame G ...

Page 267: ...ide remove the sealing cover by unscrewing the two fixing nuts Operate in the same way to remove the left sealing cover Remove the components in the following sequence Passenger and rider seat Fuel tank Air filter compartment the reassembly procedures of the components indica ted are described in chapter C Bodywork 3 G ...

Page 268: ... chapter F Suspensions and wheels chapter H Brakes and chapter L Cooling and lubri cating system Insert the support no 800097867 under the engine assembly taking care to position it as indicated in the figures Lower the motorcycle and remove the lift no 800095807 4 Frame G Utilising the lift no 800095807 equipped with the pin no 800095808 lift up the front part of the motorcycle ...

Page 269: ...e the wiring from the bands fixing it to the frame 5 G 1 2 Remove the two fixing screws 1 of the front headlight on the sides Take care to slide the adjuster out of its seat when the headlight is removed from the support Before removing the front headlight disconnect the connector 2 placed in the rear part of the headlight Then remove the headlight support and the instrument panel as described in ...

Page 270: ... and wheels 1 Remove the ignition switch and the cooling system complete with the expansion tank as described in chapter L Cooling and lubricating system 6 Frame G Protect the area around the fluid chamber with a cloth or paper Remove the union and discharge the clutch fluid from the system into an appropriate container ...

Page 271: ...the support plate of the throttle body A Fleet the accelerator control wiring and extract the pawl A of the opening wiring Carry out the same operation on the pawl of the closing wiring 1 Disconnect the connector 1 of the control of the throt tle body potentiometer from the main wiring 7 G ...

Page 272: ... Slacken the bands 1 fixing the throttle body to the air intake of each cylinder Disconnect the connections relative to the injectors of each cylinder Remove the complete throttle body assembly 8 Frame G ...

Page 273: ...onnector Unscrew the earth connection on the engine head cover and free the coil wiring from the frame by remo ving the two fixing bands then slide it out on the right side Operating on the right side of the motorcycle unscrew and remove the two fixing screws of the rear sealing protection then free the protection Operate on the left side to remove the left rear sealing protection 9 G ...

Page 274: ...le remove the supports of the tubing for checking the suc tion by unscrewing the screw fixing the support to the frame Remove the two rubber bands so to free the wiring from the frame Slide the CPU out from the fixing support fixed to the frame 10 Frame G ...

Page 275: ...Frame Slide out the main wiring and fold it backwards on the rear sub frame Fix the main wiring to the sub frame with an elastic band 11 G ...

Page 276: ...cle unscrew and remove the front screw fixing the engine cylinder head to the frame and collect the eccentric washer Operating on the right side unscrew and remove the rear nut fixing the engine assembly to the frame 1 Operating on the left side extract the pin 1 12 Frame G ...

Page 277: ...emove the screws fixing the frame tothe union plates from both sides Remove the frame rotating the steering head housing upwards Frame check Accurately clean the conical seats of the steering head housing 13 G ...

Page 278: ... figure is not defor med as a consequence of accident damage Check that there are marks of evident breakages along the frame tubes If damage is found substitute the frame Clean and examine the contacts between the frame and the engine and also between the frame and union plates 14 Frame G ...

Page 279: ...Frame 15 G ...

Page 280: ...rame G FRAME CONTROL REFERENCE MEASUREMENTS To carry out a detailed check of the frame herewith below are the reference measurements that are of fun damental importance for the correct condition of the frame ...

Page 281: ...ering head housing check Check the diameter and eventual ovalisation of the steering head housing 5 mm from the lip of the bevel ling as shown in the figure Measure the ovalisation in diverse points as shown in the figure ...

Page 282: ...U support plate anti vibration rubbers and the rubber protection These components can be mounted onto the new frame after having effectuated a thorough check on their condition For the stamping and the homologation labels of the new frame contact the MV AGUSTA service centre Thoroughly clean the matching surfaces of the frame engine cylinder head and frame union plates ...

Page 283: ...Frame 19 G With regards to the positioning of the cables fasteners and various wiring consult the various tables shown in the F4 Brutale ORO S Spare Parts Catalogue Code 800099359 ...

Page 284: ...by letting the sub frame drop into position by its own weight Utilise AGIP GREASE 30 for the screws PART DESIGN NO DESCRIPTION DIM TORQUE PRESSURE N m Kgm 1 800084869 Front engine mounting screw M12x1 25 55 60 5 5 6 0 2 800084866 Upper engine mounting screw M12x1 25 55 60 5 5 6 0 3 800084865 Lower engine mounting screw M12x1 25 55 60 5 5 6 0 4 800084867 Plate frame screw M12x1 25 55 60 5 5 6 0 5 8...

Page 285: ...Frame 21 G ...

Page 286: ... removal of all the neces sary components described in the previous paragraph remove the connector 1 on the generator Unscrew and remove the nut fixing the generator wiring to the system Unscrew and remove the nut fixing the starter motor wiring to the starter switch ...

Page 287: ...freed and collected as shown in the figure it is possible to remove the rear sub frame Unscrew and remove on both sides the two lower screws fixing the rear sub frame to the union plates taking care to recuperate the nuts Unscrew and remove the two upper fixing screws taking care in this case also to support the sub frame and recuperate the nuts ...

Page 288: ...the motorcycle Rear frame unit assembly Carry out the operation of reassembling the rear sub frame on the motorcycle in the reverse order of remo val taking care to tighten the fixing screws to the pre scribed torque pressure Rear sub frame fixing screw torque pressu re 24 28 N m 24 28 N m ...

Page 289: ...erating on the left side of the motorcycle unscrew and remove the two fixing screws of the side stand switch Disconnect the connector of the side stand switch from the main wiring 1 Disconnect the connector of the speed sensor 1 from the main wiring ...

Page 290: ...e the side stand assembly by unscrewing the three fixing screws 1 Slide the terminals of the connections out of fixing sup port 1 2 Gearchange lever removal Unscrew the fixing screw 1 and slide out the gear change lever 2 ...

Page 291: ... unscrewing the fixing screw 1 Remove the rear brake pump and the relative protec tion as described in chapter H Brakes The figures show the collectors when removed but the operation is still possible with the exhaust collectors assembled Disconnect the connector of the rear brake stop light from the main wiring N B ...

Page 292: ...ors fixing flanges of the cylinders 1 2 3 4 by unscrewing the fixing nuts Unhook the union spring between the compensator and the collector of cylinders 3 4 Remove the collector of cylinders 3 4 by sliding it out of the primary compensator ...

Page 293: ...ompensator and the collector of cylinders 1 2 and remove the col lector by sliding it out of the primary compensator Unhook the two connecting springs between the exhaust group and the silencers Remove the connecting plate between the two silen cers ...

Page 294: ... 30 Frame G Unscrew the screw fixing the silencers to the support Remove the upper silencer first then the lower one Unscrew the screw fixing the compensator to the frame ...

Page 295: ...ompensator by removing it from the pin on the left side of the frame Remove the chain as described in chapter F Suspensions and wheels Position an appropriate lift to support the rear suspen sion fork assembly as shown in the figure ...

Page 296: ... 32 Frame G Slacken the fixing screw of the front fork pin by 1 turn Slacken the nut on the rear suspension compensator pin Remove the engine support lower pin fixing nut ...

Page 297: ...rating on the left side extract the engine support pin Extract the bush shown in the figure from the union pla tes of the frame from both sides Remove the engine assembly from the union plates by dragging it forwards ...

Page 298: ...e fork pin fixing screw 1 taking care to recuperate the washer 2 Recuperate the spacer The spacer is present on the Brutale ORO model only Remove the right union plate Remove the rear suspension pin fixing nut and slide out the pin from the left side N B ...

Page 299: ...re to apply the prescribed grease and to tighten every fixing to the torque pressure indi cated on page 20 of this chapter 1 If it is necessary to remove the rider footrests remove them by unscrewing the two fixing 1 screws When reassembling tighten the footrest fixing screws to the prescribed torque pressure Torque pressure of the screws fixing the foo trests to the label 24 28 N m N B N B 24 28 ...

Page 300: ... 36 Frame G ...

Page 301: ...H 1 Brakes SECTION H Revision 0 ...

Page 302: ...STITUTION PAGE 10 FRONT BRAKE PUMP REMOVAL PAGE 11 FRONT BRAKE LEVER REMOVAL PAGE 12 CLUTCH LEVER REMOVAL PAGE 13 FRONT BRAKE DISCS PAGE 14 FRONT BRAKE DISC REMOVAL REMOVAL PAGE 15 REAR BRAKE SYSTEM PAGE 18 REAR BRAKE PADS SUBSTITUTION PAGE 19 SUBSTITUTION AND BLEEDING OF THE REAR BRAKE FLUID PAGE 22 REAR BRAKE CALIPER SUBSTITUTION PAGE 24 REAR BRAKE DISC PAGE 26 REAR BRAKE DISC REMOVAL PAGE 27 ...

Page 303: ...he braking area in steel Ø disc mm 310 310 Disc flanges Aluminium Steel Pincers Ø pistons mm 6 pistons Ø 22 65 Ø 25 4 Ø 30 23 Front disc thickness mm 4 8 4 8 Min pad thickness mm 1 1 A B C D E F G N m 15 20 8 23 25 38 42 16 18 16 18 8 10 Kg m ft lb Torque pressure Operation Loctite 243 For the F4 ORO Series do not apply thread locking fluid ...

Page 304: ...attachment and slide it out of its seat Remove the two right and left screws with their bushes from the mudguard FRONT BRAKE PADS SUBSTITUTION Widen the pads with a pincer so that the pistons are pushed back into their seats as shown in the figure The movement 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 flu...

Page 305: ...ure Compress the spring and extract the pin Remove the pads Every 6000 kilometres check the wear of the pads The pad thickness must not be less than 1 mm If the pads are excessively worn substitute them 5 H Front brake caliper Pads Channel Wear limit 1 mm Disc ...

Page 306: ...he pad plate direction proceeding as shown in the figure Ensure the correct assembly of the pad pla tes Tighten the pin to the prescribed torque pressure Front brake pad pin torque pressure 15 20 N m SUBSTITUTION AND BLEEDING OF THE FRONT BRAKE FLUID Place the motorcycle on a horizontal surface with the steering in a straight line Protect the area with a cloth Remove the two front brake fluid cham...

Page 307: ...e rubber tube in a suitable con tainer Slacken the bleed valve and empty the brake system Squeeze the brake lever and proceed until reaching the minimum level in the chamber top up with new brake fluid and continue the operation until brake fluid of a different colour comes out Repeat this operation on both pincers Tighten the bleed valve remove the rubber tube and insert the protection cap The qu...

Page 308: ...id DOT 4 Utilise only the prescribed brake fluid from sealed containers NEVER use old or used brake fluid If the bleeding has been done correctly the movement of the lever is short and without any elastic effect Repeat the bleeding operation if there is still spongi ness at the lever After having disconnected the rubber tube for the col lection of the fluid dry the bleed valve union 8 Brakes H ...

Page 309: ...n around the edge of the brake fluid chamber utilising a clean cloth Imperfect cleaning of this component could cause the loss of small quantities of brake fluid whilst riding Accurately clean the three elements of the brake fluid chamber cap with alcohol and dry with compressed air 9 H ...

Page 310: ...ted surfaces Clean immediately any spilt brake liquid using industrial alcohol and drying with compressed air 1 Remove the caliper union Remove the two caliper fixing screws 1 indicated in the figure Remove the brake caliper The removal operation for both the right and left front calipers is identical To reassemble the front brake calipers proceed in the reverse order to removal Tighten the relati...

Page 311: ...Avoid contact with the yes skin and nose Wash abundantly with water and call a doc tor if accidental contact occurs During the following operations avoid con tact with painted surfaces Remove the connectors of the electrical system Remove the fixing screw that fixes the pump to the handlebar Open the clamp Push down to remove the pump from the reference pin 11 H ...

Page 312: ...t the overhaul of the front brake pump assembly carefully wash and bleed the front brake system as previou sly described in this chapter FRONT BRAKE LEVER REMOVAL Unscrew the fixing nut locking the pin rotation with a screwdriver Unscrew the pin and remove it then remove the brake lever 12 Brakes H ...

Page 313: ...e Agip Grease 30 Insert the pin into the seat and screw it in until the beat is reached then tighten the nut by using a screwdriver Front brake lever nut torque pressure 8 10 N m CLUTCH LEVER REMOVAL Remove the nut shown in the figure Unscrew the pin and extract it Remove the clutch lever 13 H 8 10 N m ...

Page 314: ...RAKE DISCS Check the thickness of the front discs utilising a micro meter gauge Carry out the measurement at least at three points with 120 between them as shown in the figure Utilise a micrometer gauge for this check The minimum thickness of the discs vary with the type of disc used For brake discs with a thickness of 4 8 mm the minimum thickness is 4 5 mm This operation just be carried out on bo...

Page 315: ...s of each disc procee ding in a star like mode for the removal Visually check the discs for lines or score marks Place the milled side of the brake disc flange on a level surface with the milled side face down and utilising a micrometer gauge check that the maximum oscillation of the disc reached during a rotation of 360 does not exceed 0 3 mm Utilise a micrometer gauge for this check If the oscil...

Page 316: ...peration must be carried out only on the following model Brutale S Apply thread locking fluid to the five fixing screws of the disc Recommended thread locking fluid Loctite 243 The following operation must be carried out only on the following model Brutale ORO Apply dielectric grease to the five fixing screws of the disc Recommended grease Valvoline Tectyl 511 16 Brakes H ...

Page 317: ...ke disc screw torque pressure 23 25 N m Be careful to reassemble the discs in the original posi tions it is advisable to mark them by applying an adhe sive label This operation is important so that a good contact between the brake discs and the relative pads Reassemble the wheel pin and the wheel as described in chapter F Suspensions and wheels 17 H 23 25 N m ...

Page 318: ...n BRUTALE ORO BRUTALE S REAR BRAKE Type Steel disc Ø disc mm 210 210 Pincer Ø piston mm 4 pistons Ø 25 4 Disc thickness mm 6 6 Minimum pad thickness mm 1 1 A B C D E F G N m 220 240 15 20 16 18 16 18 18 18 20 5 7 Kg m ft lb Torque pressure Operation 243 270 ...

Page 319: ...cer Remove the exhaust protection Turn the lower silencer outwards slightly If this movement is difficult due to residues in the area of connection to the compensator clean the part applying lubricant WD 40 unblocking spray Rotate the silencer in a clockwise or anti clockwise direction alternatively to allow the lubricant to seep through 19 H ...

Page 320: ...ad To slacken the nut it is therefore necessary to turn the torque wrench in a clockwise direction Remove the rear wheel nut When reassembling tighten the rear wheel nut to the prescribed torque pressure Rear wheel nut torque pressure 220 240 N m Remove the rear wheel taking care to not hit the silen cer connecting plate If this operation is too difficult to carry out remove the silencer connectin...

Page 321: ...e seats with a consequent increase in the level of the brake fluid in the brake fluid chamber Remove the pad support pin and the relative spring Remove the pad by letting it drop down Rear brake pads Wear substitution check the first time after 1000 kilometres then every 6000 kilometres Check the wear condition and the thickness of the brake pads on the calipers 21 H Rear brale caliper Pads Channe...

Page 322: ...ue pressure 15 20 N m SUBSTITUTION AND BLEEDING OF THE REAR BRAKE FLUID The operation described herewith must be carried out with the engine cold the position of the brake fluid tank could cause grave burns To carry out this operation it is necessary to remove the passenger seat the rider seat and the fuel tank to accede to the brake fluid tank as described in chap ter C Bodywork 22 Brakes H 15 20...

Page 323: ...d is extremely corrosive Avoid contract with the eyes skin and nose Wash abundantly with water if contact is accidentally made and consult a doctor During the successive operations avoid spilling the fluid onto painted surfaces Connect a rubber tube to the bleed valve empty the system in an appropriate container by slackening the bleed valve as shown in the figure 23 H ...

Page 324: ...ee the paragraph in this chapter REAR BRAKE CALIPER SUBSTITUTION To facilitate the operation remove the brake pads as described previously Empty the system of brake fluid as described in para graph Substitution and bleeding of the rear brake fluid Remove the tubing by unscrewing the union indicated in the figure Be careful of the residue fluid that remains inside the pincer unit Remove the two scr...

Page 325: ...e brake system as pre viously described in paragraph Substitution and blee ding of the rear brake fluid Remove the clips complete with the fixing pin of the rear brake lever and the pump control fork by rotating and successively pushing inward as shown in the figu re Unscrew the union indicated by the arrow in the figure thereby freeing the pump the brake tubing The figures show the collectors whe...

Page 326: ...kets of the pump caliper hoses Tighten the fixings to the prescribed torque pressure Torque pressure pump union 16 18 N m Torque pressure of the screws fixing the brake pump to the support Screws M6 8 10 N m Screws M8 23 25 N m Conclude the operations by filling the system with brake fluid and successively bleeding the system see page 22 REAR BRAKE DISC Check the thickness of the rear brake disc S...

Page 327: ...cle and rotating the disc to facilitate the removal of the nuts Check the planarity of the rear brake disc by utilising a micrometer gauge and placing the disc on a level work surface Utilise the same procedure adopted for the front wheel discs The planarity value must not exceed 0 3 mm Utilise a micrometer gauge with support to carry out this check Check the thickness of the rear brake disc by ut...

Page 328: ...he nuts screwed in lightly and brought into con tact with the disc surface After this operation tighten the four nuts in a cross like mode Rear brake disc nut torque pressure 18 20 N m Apply Loctite 270 Conclude the reassembly operations of the various components by following the procedures previously described in these paragraphs in reverse order 28 Brakes H 18 20 N m ...

Page 329: ...L 1 Cooling system and lubrication system SECTION L Revision 0 ...

Page 330: ... EXTRACTION PAGE 5 EXPANSION TANK REMOVAL PAGE 5 DISASSEMBLING WATER RADIATOR PAGE 8 DISASSEMBLING ELECTRIC FAN PAGE 12 CHECKING COOLING FAN STARTER PAGE 13 COOLANT TEMPERATURE SENSOR PAGE 15 REMOVING THERMOSTAT VALVE PAGE 16 REASSEMBLING THERMOSTAT VALVE PAGE 18 REASSEMBLING EXPANSION TANK PAGE 20 ASSEMBLING WATER RADIATOR PAGE 22 REMOVING OIL RADIATOR PAGE 27 REASSEMBLING OIL RADIATOR PAGE 31 ...

Page 331: ...hecking disposing of or overhauling any component relevant to the cooling and lubrication perform some preliminary operations system 1 Let the engine cool down 2 Remove the passenger and pilot seat right and left side panel fuel tank and air filter compartment as descri bed in the chapter C Superstructures ...

Page 332: ...heck the entire 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 pressure to avoid damaging the radiator EXPANSION TANK CAP CHECK Check the release pressure of the radiator cap by utili sing the appropriate tester as follows Apply the cap to the tester...

Page 333: ...coolant flows into the container Wait until all the engine coolant has dripped out of the cooling system Recover the coolant in an appropriate vessel Do not drain liquid into the environment 1 EXPANSION TANK REMOVAL After having drained the cooling system as described in the previous paragraph it is necessary to remove the ignition switch you should remove the fuel tank and the air filter compartm...

Page 334: ...ferent from those indicated it must be substituted for a new one If so proceed with its complete removal Cooling system and lubrication system 1 2 Disconnect the connector 1 of the ignition switch and remove its rubber clamp 2 acting on the right side of the motorcycle 1 On the right side of the motorcycle remove the clamp 1 connecting water radiator breather pipe to the expansion tank using speci...

Page 335: ...screws 1 2 1 On the left side of the motorcycle remove the clamp 1 connecting the water radiator charging pipe to the expansion tank using a specific pliers CLIC R 205 and its rubber clamp placed near the fluid supply tank Specific tool CLIC R 205 Disconnect the water radiator charging pipe 2 7 L 1 Remove the expansion tank 1 releasing it from its seat on the frame and lifting it in the rearward o...

Page 336: ...ling system and lubrication system 2 1 DISASSEMBLING WATER RADIATOR Remove the upper 1 and side 2 protections of the water radiator unscrewing the respective fixing screws on both sides of the radiator 1 Remove the oil radiator protection 1 unscrewing the two fixing screws L 8 ...

Page 337: ...grid 1 taking it out from its seat 1 Disconnect the connector 1 of the water radiator elec tric fan on the right side of the motorcycle 9 L 1 Disconnect the connector 1 of the water temperature sensor to the instrumentation panel on the left side of the motorcycle ...

Page 338: ... the clamp 1 on the water suction pipe cou pling from the pump to the radiator using the specific pliers CLIC R 205 Specific tool pliers CLIC R 205 1 Remove the clamp 1 on the water inlet pipe coupling to the radiator from the thermostat valve using the spe cific pliers CLIC R 205 Specific tool pliers CLIC R 205 L 10 ...

Page 339: ...e of the motorcycle in order to the release the water suction pipe coupling 1 from the pump to the radiator 1 Release the water inlet pipe coupling to the radiator 1 to the radiator from the thermostat valve 11 L Remove the radiator fixing screws on the left side of the motorcycle ...

Page 340: ... fan 2 and protecting 3 the support 4 Cooling system and lubrication system A Remove the radiator moving it right in order to release it from the peg A on the frame support 1 1 DISASSEMBLING ELECTRIC FAN Unscrew the three screws 1 and remove the comple te fan support L 12 ...

Page 341: ...fan turns at maximum speed the ampmeter should indicate not more than 5 ampe re If the motor does not turn substitute the fan motor unit with a new one To carry out the above indicated test it is not necessary to remove the fan motors from the engine 2 1 4 3 Insert the electric fan 2 on its support 4 Tighten the three fixing nuts 1 putting the protection 3 between support and electric fan Torque w...

Page 342: ...ectric cooling fan as indicated in the figure Insert the electrical connector into its tongue support in the area indicated of the fan frame and fix the cable using the appropriate tear clamps 1 as shown in the figure To avoid possible contact between the elec tric lead and the exhaust tube ensure that the lead is correctly positioned L 14 2 ...

Page 343: ...ct the coolant temperature sensor to an ohm meter and immerse it into heated oil as indicated Heat the oil to slowly raise the temperature and observe the thermometer and the ohm meter If the resistance of the coolant temperature sensor does not change as indi cated in the table then the sensor must be substituted Special tool 09900 25008 Multi tester Temperature Average resistance 20 C Approx 3 7...

Page 344: ...rting the coolant tem perature sensor It could be damaged if it is knocked When fully tightened check that the connector is pla ced along a horizontal axis with the rear projection pla ced vertically REMOVING THERMOSTAT VALVE Disconnect the electric wiring from the water tempera ture sensor 1 to gearcase Remove the fixing screws 1 of the thermostat valve cover The figure show an engine assembly re...

Page 345: ...water with a heat source and observe the increase in temperature of the thermometer Observe the temperature at the moment of opening of the thermostat The temperature at which the thermostat commences to open should be between the indicated values 2 1 Standard Thermostat opening temperature 74 5 78 5 C Continue to heat the water to increase the tempera ture When the temperature of the water reache...

Page 346: ...ot in good condition substi tute it with a new one Apply a thin layer of silicone grease Recommended grease Silicone Grease 1 Insert the thermostat 1 into its seat within the cover 2 3 During the assembly of the thermostat ensure that the hole 2 on the external flange of the thermostat is ali gned with the curved working 3 on the cover Cooling system and lubrication system L 18 ...

Page 347: ...ete with ther mostat onto the engine Tighten the three fixing screws 1 to the prescribed torque pressure Torque pressure 10 N m 1 Tighten the H2O sensor 1 for gearcase ensuring that the connector is in horizontal or standing position 1 Insert the connector 1 in the thermal switch 10 N m ...

Page 348: ...ion tank on the frame if the opera tion is difficult slightly turn the tank clockwise 2 4 1 3 5 5 Insert the radiator water breather pipe 1 and the over flow pipe 2 inside the seats on the plastic clip 3 Reassemble and fix the ignition switch fixing support 4 using the four screws 5 Cooling system and lubrication system L 20 ...

Page 349: ...fix it using the three rubber clamps 1 as shown in the figure Ensure that the placement follows the figure and inclu des also the clutch control piping 2 2 1 Put the overflow pipe 1 on the nozzle of the expan sion tank cap 2 again 1 2 Assemble the ignition switch 1 securing it on the fixing support using the two screws 2 ...

Page 350: ...NG WATER RADIATOR On the right side of the motorcycle insert the radiator right support equipped with rubber bulb in the frame peg A Cooling system and lubrication system L 22 On the left side of the motorcycle insert the water radiator connecting pipe 2 to the expansion tank Secure it using a clamp 1 CLIC R 205 with relevant specific pliers Specific tool CLIC R 205 ...

Page 351: ... CLIC R 96 300 white Specific tool pliers CLIC R 205 Insert the return pipe coupling that connects the radia tor with the water pump Secure it using a clamp CLIC R 96 300 white On the left side of the motorcycle insert the radiator fixing screw and tighten it to the prescribed torque wrench Torque wrench setting of the radiator fixing screw 10 N m 10 N m ...

Page 352: ...C R 96 120 black Connect both the pipe and the electric fan wiring by using a rubber clamp 2 Specific tool pliers CLIC R 205 1 Assemble the protective grid 1 inserting it in its seat Cooling system and lubrication system 1 On the right side of the motorcycle connect the electric fan connector 1 with the main wiring L 24 2 ...

Page 353: ... the side 2 and upper 1 protections secu ring them on the radiator using the respective fixing screws 1 Perform the same operation for assembling the oil radiator protection 1 Assemble the plastic upper protection 1 and secure it using the two fixing screws ...

Page 354: ...he expansion tank For assembling repeat the same phases described for disassembling the components but reversing the order Reassemble the following components in order Air filter compartment Fuel tank Cooling system and lubrication system Fill the system using the appropriate fluid L 26 ...

Page 355: ...sel Do not drain liquid into the environment Verify the coolant level inside the expansion tank again It must reach the line shown in the figure keeping sli ghtly over the MIN reference If the level is lower than the line shown reset it adding new liquid from the filling cap restart the engine until the temperature is reached and wait for the fan comes into operation at least twice Shut off the en...

Page 356: ...of the fixing flange 1 from the cylinders During this operation pay attention to the exhaust pipes in order to avoid scorching if the engine is still hot Cooling system and lubrication system 1 Remove the filling cap 1 on the right side of the motorcycle in order to facilitate the oil spill Wait for the complete draining of the lubrication system L 28 ...

Page 357: ...tor perform the following operation Remove the oil delivery and return pipings connected with the nipples of the oil piping support unscrewing the fixing nuts If the oil radiator should be only removed from its position instead of being replaced don t intervene either on pipings or on unions 1 Release the junction spring 1 between compensator and manifold of cylinders 3 and 4 Remove the manifold o...

Page 358: ...erted in the rubber bulb support 1 on the right side Cooling system and lubrication system 1 Remove the engine radiator support fixing screw pla ced on the left side This figure and the next ones show an engine assembly which the water radiator has been removed from but the described operations can be performed also when the radiator is assembled L 30 N B ...

Page 359: ...DIATOR Insert the support peg in the support 1 on the right side making the oil radiator move from left to right 1 Connect the engine radiator anchor rod 1 on the left side 1 Put the radiator engine support on the left side again and secure it tightening the screw ...

Page 360: ... pipe fixing nuts to the radiator to the pre scribed torque wrench Torque wrench setting 18 20 N m Reassemble the exhaust manifolds of the cylinders 1 2 3 4 In order to facilitate the reassembly of the manifolds you should place the fixing flange before placing manifolds on the engine Insert the flange inside and then turn it at last put the manifold flange assembly on the fixing stud 1 Insert the...

Page 361: ...ling the plug verify the complete clea ning and the good condition of the seal On the oil drain plug there is a magnet for attracting any ferrous residuals which could form in the engine during the rotation Reassemble the engine oil drain plug and tighten it to the specific torque wrench Torque wrench setting for oil drain plug 35 N m Fill the circuit complying with the specifications descri bed i...

Page 362: ...vel 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 Check any oil leakages Avoid making the engine turn with the oil level lower than the minimum level this can impair the operation of the different parts of the engine If the oil level after the reset is uppe...

Page 363: ...Special tools 1 M SECTION M Revision 0 ...

Page 364: ... 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 parts catalogue ...

Page 365: ...cinetti forcellone puller bushing 6 800092862 1 Estrattore cuscinetti Front wheel ruota anteriore bearings puller 7 800092863 1 Chiave per CPC CPC spanner 8 8000A1953 1 Perno 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 assembly fascette clic R disassem...

Page 366: ...Special tools M 4 ...

Page 367: ...a settaggio Rear suspension sospens posteriore setting rod 6 800095807 1 Cavalletto anteriore 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 base base di sterzo plate 10 800097889 1 Estrattore cuscinetto Steering pin perno di sterzo bearing extractor 11 8000...

Page 368: ...Special tools M 6 ...

Page 369: ...ible supporto coupling support parastrappi locking tool 11 800094798 1 Attrezzo smontaggio Valve rubber caps gommini valvola removal tool 12 62N115538 1 Rosetta elastica Spring washer 13 8C0069056 3 Vite TEF M8x30 Screw M8x30 14 800094796 1 Attrezzo montaggio Valve assembly smontaggio valvole disassembly tool 15 800051521 2 Vite M4x6 Screw M4x6 16 800095429 1 Tampone controllo Gauge pad 17 8000955...

Page 370: ...Special tools M 8 ...

Page 371: ...embly 2 8000A0965 1 Supporto per Fuel tank serbatoio benzina support 3 8000A1876 1 Cavo elettrico Wire cable 4 80A0A1875 1 Tubo mandata Fuel delivery benzina completo pipe assembly 5 8000A1875 1 Tubo ritorno Fuel return benzina completo pipe assembly 6 8000A4317 1 Attrezzo per Oil filter filtro olio removal tool 7 8000A4686 1 Attrezzatura per CO control controllo CO tool assembly ...

Page 372: ...Special tools M 10 ...

Page 373: ... 1 Torque pressures N SECTION N Revision 0 ...

Page 374: ...ANDLEBARS AND CONTROLS PAGE 3 FRONT SUSPENSION PAGE 3 REAR SUSPENSION PAGE 3 FAIRING AND MUDGUARDS PAGE 3 ELECTRICAL SYSTEM PAGE 4 FUEL FEED PAGE 4 WHEELS AND BRAKES PAGE 4 EXHAUST SYSTEM PAGE 4 INSTRUMENTATION PAGE 4 COOLING PAGE 4 LUBRICATION PAGE 4 NUTS AND SCREWS NOT INDICATED IN THE TABLE PAGE 4 ...

Page 375: ...readings only With grease on first threadings only Without grease Without grease Without grease Without grease Lubricate with engine oil Lubricate with engine oil In contact In contact In contact In contact En apoyo With grease on first threadings only With grease on first threadings nut only Do not apply grease on the conical part of the nut With copper CU grease on the first threadings only With...

Page 376: ...ing and false link pins With grease on first threadings only With grease on first threadings only With grease on first threadings only With grease on first threadings only With grease on first threadings only With grease on first threadings only With grease on first threadings only With grease on first threadings only In contact With grease on first threadings only With grease on first threadings ...

Page 377: ...Diagnostics 1 O SECTION O Revision 0 ...

Page 378: ...itute Defective thermo switch connection Deoxidise replace Defective fan Deoxidise replace LIGHTING INDICATOR SYSTEM Front rear sidelights do not function C3 fuse burnt out Substitute Defective C3 fuse connection Deoxidise replace Defective ignition switch Substitute Defective ignition switch connection Deoxidise replace Burnt out bulbs Substitute Defective bulb connections Deoxidise replace Defec...

Page 379: ...not function Defective temperature sensor Substitute Defective temperature indicator connection Deoxidise replace Defective instrument panel Substitute Defective instrument panel connection Deoxidise replace The oil warning light does not function Defective oil pressure sensor Substitute Defective oil pressure sensor connection Deoxidise replace Defective instrument panel Substitute Defective inst...

Page 380: ...et Defective fuel pump Substitute IGNITION SYSTEM Spark plug does not function F6 fuse burnt out Substitute Defective F6 fuse connection Deoxidise replace E5 fuse burnt out Substitute Defective E5 fuse connection Deoxidise replace G7 fuse burnt out Substitute Defective E5 fuse connection Deoxidise replace Defective power relay Substitute Defective power relay connection Deoxidise replace Defective...

Page 381: ... wheel bearings Tighten Fixing nut not tightened Tighten Suspension screws not tightened Tighten Damaged suspension bearings Substitute Rear wheel does not turn easily Damaged bearings Substitute Wheel hub circlip out of its seat Check Brake pads excessively brush against the disc Check Bent brake disc Substitute Damaged transmission chain Substitute REAR SUSPENSION Rear suspension too spongy Insu...

Page 382: ... tube fixings Tighten Low engine performance Damaged exhaust tube Substitute Slack tube fixings Tighten COOLING SYSTEM Engine temperature too high Low engine coolant level Top up Defective cooling fan Substitute Defective coolant expansion chamber cap Substitute Defective fan thermal switch Substitute Defective temperature sensor Substitute Thermostat is blocked in the closed position Substitute R...

Page 383: ...Analytical index 1 P SECTION P Revision 0 ...

Page 384: ...11 Oscillating arm bearings B 74 Periodical maintenance schedule B 9 Rear shock absorber B 74 Rear wheel hub B 74 Screws and nuts B 76 SIde stand B 75 Spark plugs B 33 Steering B 69 Technical data B 3 Technical information B 3 Throttle body adjustment and tuning B 50 Transmission chain B 69 Tube band fasteners B 76 Tyres B 72 Valve mechanism adjustment B 22 Wheels B 73 Chapter C Bodywork AIr filte...

Page 385: ...cator E 43 Oil pressure sensor E 41 Parts list E 6 Right direction indicator E 43 Rpm indicator E 43 Semiconductor parts E 4 Slde stand switch E 36 Spark plugs E 37 Speed sensor E 43 Starter motor assembly E 33 Starter motor check E 33 Starter motor removal E 32 Starter relay activation E 42 Starter system E 23 Switches E 46 Chapter F Suspension and wheels Front fork overhaul F 11 Front fork F 10 ...

Page 386: ...L 5 Expansion tank cap check L 4 Expansion tank removal L 5 Reassembling expansion tank L 20 Reassembling oil radiator L 31 Reassembling thermostat valve L 18 Removing oil radiator L 27 Removing thermostat valve L 16 Chapter M Special tools Maintenance tools M 2 Chapter N Torque pressures Torque pressures cycle parts excluding engine BRUTALE ORO Cooling N 7 Electrical system N 6 Exhaust system N 7...