MV Agusta F4 750, Instructions Manual

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

Page 2: ...NSION TANK REMOVAL PAGE 5 RADIATOR REMOVAL PAGE 8 WATER OIL HEAT EXCHANGER PAGE 11 ELECTRIC FAN REMOVAL PAGE 11 RADIATOR GROUP ASSEMBLY PAGE 12 COOLANT TEMPERATURE SENSOR PAGE 20 FAN THERMAL SWITCH PAGE 21 THERMOSTAT PAGE 22 EXPANSION TANK ASSEMBLY PAGE 26 RADIATOR GROUP ASSEMBLY TO THE MOTORCYCLE PAGE 29 FILLING THE COOLING SYSTEM PAGE 33 SYSTEM FUNCTIONING CHECK PAGE 34 ...

Page 3: ...any component relative to the cooling system carry out cer tain preliminary operations 1 Let the engine cool down 2 Remove the under engine fairing the left and right fairing side panels the tail unit the right and left side pan els the fuel tank and the air compartment as described in chapter C Bodywork ...

Page 4: ...he 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 util ising the appropriate tester as follows Apply the cap to the tester as in...

Page 5: ... switch by unscrewing the two screws 1 5 L ENGINE COOLANT EXTRACTION Open the cap of the expansion tank Empty the cooling system of the coolant as follows Place under the engine a container to collect the dis charged coolant Remove the discharge screw 1 situated on the water pump 2 Make sure the coolant flows into the container 1 2 Wait until all the engine coolant has dripped out of the cooling s...

Page 6: ...ight side of the motorcycle 1 Remove the connection tube shown in the figure Check the diameter of the tube that has just been removed If the external diameter Ø 10 5 mm and the internal diameter Ø 6 5 mm the tube can be reused for the successive assembly If the dimensions of the tube are different from those indicated it must be substituted for a new one If so proceed with its complete removal 2 ...

Page 7: ...L To extract the tube it is necessary to free it from its fix ings as indicated in the figure Disconnect the radiator charging tube Remove the band fasteners utilising the CLIC 205 pin cers Special tool CLIC 205 pincers ...

Page 8: ...em Special tool CLIC 205 pincers Remove the expansion tank RADIATOR REMOVAL Remove the band fastener of the thermostat connect ing tube of the radiator Special tool CLIC 205 pincers Remove the band fastener of the radiator tube metal tube Special tool CLIC 205 pincers ...

Page 9: ...ystem Disconnect the tube coming from the heat exchanger Special tool CLIC 205 pincer 9 L Suck out the residue coolant from inside the lower radi ator Disconnect the connector of the water temperature sensor 1 1 ...

Page 10: ...iator Extract the screw and the flanged aluminium bush The radiator is freed from its supports N B Carry out the said operations with care Pour the remaining coolant inside the radiator into an appropriate container Do not dispose of engine coolant in the envi ronment Collect in an appropriate container and dispose of it according the norms in force N B 2 3 ...

Page 11: ...erhaul of this part consult chap ter Engine ELECTRIC FAN REMOVAL Remove the two rubber band fasteners Unscrew the three screws of the upper fan and remove the fan unit When substituting the fan it is necessary to remove the three screws indicated in the figure The procedure is the same for the lower fan in this case though the fan protection is fixed to the radiator by four screws ...

Page 12: ...l screwdriver Cooling fan motor check To check the efficiency of the fan motors it is necessary to connect them as indicated in the figure utilising a voltmeter and ampmeter During the check the fans must be fed by 12V and this test can be carried out on a work surface connecting a 12V 9Ah battery or on board the motorcycle The voltmeter is to check that the battery feeds the motor at 12V When the...

Page 13: ...reviously assembled electric cooling fan onto the upper radiator Tighten the screws 4 to the prescribed torque pres sure Torque pressure 5 6 N m 1 2 3 5 6 N m 5 6 N m 4 The following phase applies only to the following mod els F4 S and F4 S 1 1 from frame registration num ber 004718 Make sure that the temperature resistant sheathing 5 is inserted on the upper fan wiring 5 ...

Page 14: ...an frame Position a strap fastener 1 in the position indicated in the figure Once fixed the wiring should look like the wiring in the figure To avoid possible contact between the elec tric lead and the exhaust tube ensure that the lead is correctly positioned Assemble the anti vibration rubbers 1 into their rela tive seats situated on the left and right side of the lower radiator 2 1 1 ...

Page 15: ...ush 1 inside the anti vibration rub ber situated on the left side of the lower radiator Assemble the two radiators Insert the T E F M6 L 25 mm screw 1 and tighten Assemble the rubber radiator connecting hose 1 as indicated in the figure 1 1 1 ...

Page 16: ...hown in the figure A different position of the head of the fastener could create interference with the fairing side panel Insert the anti vibration rubbers 1 two for each side of the radiator into their relative upper supports 1 Insert the flanged bush into the left support of the upper radiator Ensure that the flanged part faces outwards ...

Page 17: ...registration 004718 At the point of entry into the body of the lower fan the electric lead must be placed as shown in the figure to avoid accidental damage by the blades of the fan and also with the exhaust tube of the engine Place the tem perature resistant sheathing 1 on the electric lead sur face Fasten the electric lead to the support of the lower fan using a metal clamp 2 as shown in the figu...

Page 18: ... operation To avoid possible contact between the elec tric lead and the exhaust tube ensure that the lead is correctly positioned The following phases are to be carried out on all F4 models Apply the two band fasteners 1 to the lead in the posi tions indicated in the figure Carry out the pre assembly of the radiator group fixing support that fixes the radiator to the engine L 18 1 min 5 mm min 5 m...

Page 19: ...ers onto the cooling fan support of the lower radiator The assembly of the new radiator group has been completed At the end of the assembly operation the radiator group should look like the group indicated in the figure The radiator group can be mounted onto the motorcy cle ...

Page 20: ...rature 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 indicated in the table then the sensor must be substituted Special tool 09900 25008 Multi tester Temperature Average resistance 20 C Approx 3 747 Kohm 50 C Approx 1...

Page 21: ...ch remains open when the temperature of the coolant is low and it closes when the temperature of the coolant reaches approximately 92 C thereby activating the fan After having emptied the cooling system as described previously remove the connector 1 as indicated in the figure Remove the switch from the thermostat cover 1 Thermal switch check Check that the thermal switch closes on reaching the spe...

Page 22: ...Remove the cover of the thermostat 2 Remove the thermostat 3 1 2 3 Cooling system L 22 THERMOSTAT Removal Remove the three fixing screws 1 of the thermostat cover 2 ...

Page 23: ...se in temperature of the thermometer Observe the temperature at the moment of opening of the thermostat The temperature at which the thermo stat commences to open should be between the indi cated values 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 reaches the spec ified value the thermostat should be r...

Page 24: ...ilised If the O ring is not in good condition substi tute it with a new one Apply a thin layer of silicone grease Recommended grease Silicone Grease Insert the thermostat 1 into its seat within the cover During the assembly of the thermostat ensure that the hole 2 on the external flange of the thermostat is aligned with the curved working 3 on the cover 1 1 2 3 ...

Page 25: ...sure Torque pressure 10 N m Insert the cover of the thermostat complete with ther mostat onto the engine Tighten the thermal switch of the electric fan 2 ensur ing that the connector is in a vertical or horizontal posi tion Insert the electric wiring onto the connector 3 1 2 3 10 N m ...

Page 26: ... in respect of the expansion tank as indicated in the figure Position the expansion tank on the frame Insert the engine coolant filler tube and the overflow tube inside the plastic clip 1 2 Place the tube close to a frame tube Fix it with a rubber band fastener 2 ...

Page 27: ...r Lower fastener 2 CLIC R 96 350 white colour To allow the correct assembly of the left fairing side panel and before fixing the rubber fastener check that the placing of the components are as follows Fix the two rubber tubes to the frame as shown in the figure 2 1 FRAME TUBE RUBBER FASTENER CLUTCH TUBE RADIATOR DISCHARGE TUBE OVERFLOW TUBE ...

Page 28: ...he radiator filler tube Fix with a band fastener CLIC R 96 170 black colour Special tool CLIC 205 Assemble the rubber protection band 1 Tighten the fasteners indicated in the figure using the CLIC 205 pincer Special tool CLIC 205 1 ...

Page 29: ... of the motorcycle Fix the connector to the frame utilising rubber band fastener RADIATOR GROUP ASSEMBLY TO THE MOTORCYCLE Assemble the radiator group to the motorcycle Insert the thermostat radiator connecting hose Tighten utilising a band fastener CLIC R 96 300 white colour Special tool CLIC 205 ...

Page 30: ...Insert the fixing screw of the radiator and tighten to the prescribed torque pressure Torque pressure 10 N m Assemble the metal tube lower radiator connecting hose Ensure that the length of hose pushed onto the metal tubes is equal on both sides Position the band fastener approximately 5 mm from the end 10 N m ...

Page 31: ...o that the clip part is pointing downwards Utilise band fasteners CLIC R 96 300 white colour Special tool CLIC 205 pincer Connect the tube coming from the heat exchanger Tighten utilising a band fastener CLIC R 96 145 black colour Special tool CLIC 205 Connect the connector of the water temperature sen sor 1 1 ...

Page 32: ...imensions Fastener 1 Length 82 mm Fastener 2 Length 82 mm Fastener 3 Length 62 mm Fastener 4 Length 82 mm 3 2 4 1 Connect the tube for the discharging of the cooling sys tem Utilise band fastener CLIC R 96 120 black colour Special tool CLIC 205 pincer Connect the two connectors of the fans situated on the right side of the motorcycle ...

Page 33: ...ry out a final check before proceeding with successive operations For an eventual codification and definition of the parts consult the spare parts cata logue Table G 17 Insert the pin for the fairing 1 and tighten the two lat eral screws 2 2 1 FILLING THE COOLING SYSTEM Remove the cap of the upper expansion tank Fill the system with the appropriate coolant N B ...

Page 34: ...ect level Unscrew the filler plug 1 shown in the figure and insert the correct quantity of oil 1 SYSTEM FUNCTIONING CHECK Assemble the following components in order Right air intake Left air intake Air filter compartment Fuel tank For the assembly operations assemble in reverse order of removal Fill until reaching the MAX level indicated on the expansion tank Close the cap ...

Page 35: ...the level of engine coolant inside the expansion tank It should be at the level shown in the figure a little below the MAX level If the level is less than the indicated line open the expansion tank cap and top up with new coolant Switch on the engine again and bring it to running tem perature and wait until the fan cuts in at least twice Switch off the engine and wait for the temperature to drop E...

Page 36: ...Cooling system L 36 ...