maintenance manual - team double 3 racing intervals indicated in the periodic maintenance and lubri-...

Maintenance manualEnglish Version

chap. Subjects covered page

1 MAINTENANCE 3

1.1. Symbols 3

1.2. Tables of scheduled maintenance and checks 4

1.3. Tools and accessories supplied 14

1.4. Table of lubricants and fluids 15

1.5. Removing/fitting the side fairing 16

1.6. Checking the engine oil level 18

1.6.1. Topping up the engine oil level 19

1.7. Checking the coolant level 21

1.7.1. Topping up the coolant level 22

1.8. Checking the wear of the brake pads 24

1.9. Checking the brake fluid level 25

1.10. Checking the clutch fluid level 27

1.11. Checking and replacing the tyres 28

1.12. Checking and lubricating the drive chain 34

1.13. Checking the idle speed 38

1.14. Replacing parts - General information 39

1.14.1. Replacing the fuses 39

1.14.2. Replacing the license plate light bulb 44

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1.15. Battery 47

1.16. Cleaning the motorcycle 49

1.17. Prolonged inactivity 51

2 TROUBLESHOOTING FLOW CHART 52

2.1. Engine problems 52

2.2. Electrical equipment problems 57

3 TECHNICAL INFORMATION 60

3.1. Motorcycle overview 60

3.1.1. Front brake circuit 62

3.1.2. Rear brake circuit 63

3.1.3. Clutch circuit 64

3.1.4. Engine lubrication 65

3.1.5. Coolant circuit 66

3.1.6. Fuel system 67

3.2. Specifications 68

3.3. Bodywork parts reference colours 76

3.5. Frame parts reference colours 78

CONTENTS

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11.1. Symbols

Sections of text that are particularly important in terms of personal safety or possible damage to themotorcycle are marked with the following symbols:

Danger - Failure to observe these prescriptions, even in part, may pose a serious hazardto the driver’s and other people’s safety.

Caution - Failure to observe these prescriptions, even in part, may result in damage to themotorcycle.

The following symbols give an indication of who is supposed to perform the different adjustments and/ormaintenance operations:

Information on operations that can be carried out by the user.

Information on operations that must be carried out only by authorized personnel.

The following symbols are used to provide further information:

The “ ” symbol points out the requirement to use a tool or a special equipment inorder to correctly perform the described operation.

§ The “ § ” symbol refers the reader to the chapter identified by the number that follows.

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1.2. Tables of scheduled maintenance and checks

The main periodic checks and maintenance operations areshown in the following tables. These operations are necessaryto keep the motorcycle safe and in perfect running order.

The intervals indicated in the periodic maintenance and lubri-cation tables must be intended as a general guide under nor-mal riding conditions. It could be necessary to reduce theseintervals according to the climate, the ground conditions, thegeographic position and the conditions of use.

Some of the operations can be carried out by the user, provid-ing he or she possesses the requisite skills. If unskilled, havethe operations performed by an authorized service centre.

As a rule maintenance operations must be performed whilethe motorcycle is on the rear stand after switching off theengine and setting the start switch to OFF. On the contrary,while checking the fluid levels it is advisable to keep the motor-cycle in an upright position without using the rear stand.

After the first 36,000 km (22,400 mi) the operations must beperformed at the same intervals shown in the tables.

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WARNING• Impropriety or lack of recommended maintenance operations can lead to an increase ofthe risk of accidents and damage to the motorcycle.• Always use genuine MV Agusta spare parts. Using non-genuine spare parts can acceler-ate the wear of your motorcycle and shorten its life.• Failure to perform the recommended operations, as well as using non-genuine spareparts, could cause the warranty not to be operating.• To replace or top up the lubricants and fluids of your motorcycle, use only the productsgiven at paragraph 1.4.

WARNINGIf you use the motorcycle on race track, we recommend to have the bike checked beforeand after using it by skilled personnel belonging to the MV Agusta Service Centers network.Using the motorcycle on road track is allowed only occasionally and, however, not for com-petitive purpose, even during amateur events.Using the motorcycle on road track could cause a considerable increase of the wear of itscomponents, which would bring to a reduction of their life duration with reference to a nor-mal use on road or highway route.

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Tables of scheduled maintenance

0 1000 6000 12000 18000 24000 30000 36000(600) (3800) (7500) (11200) (14900) (18600) (22400)

Pre-delivery

DESCRIPTION OPERATION

km (mi) covered

Service coupon A B C D E F G

Replace( Use only MV Agustagenuine spare parts )

Check level Every time vehicle is used

Engine oilRenew

! ! ! ! ! ! !

At least once a year

Engine oil filter! ! ! ! ! ! !

Every time engine oil is changed

Check / Restore level Every time vehicle is used

Coolant Check / Restore level ! ! ! ! ! ! ! !

Renew At least every two years

Cooling system Check for leakage ! ! ! ! ! ! ! !

Electric fans Check operation ! ! ! ! ! ! ! !

Valves Check / Adjust ! ! !

Timing chainCheck ! !

Replace !

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0 1000 6000 12000 18000 24000 30000 36000(600) (3800) (7500) (11200) (14900) (18600) (22400)

Pre-delivery


km (mi) covered


Timing movable shoe

Check / Replace ! !

Replace!

Every time timing chain is replaced

Timing chain stretcher Check / Replace ! ! !

Spark plugsCheck / Replace ! ! !

Replace ! ! !

Fuel filter Check / Replace ! ! !

Throttle body Check and Adjust ! ! ! ! ! ! !

Air filter Check / Replace ! ! ! ! ! !

Check level Every time vehicle is used

Brakes / Clutch fluidCheck level ! ! ! ! ! ! !

Renew!

At least every two years

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0 1000 6000 12000 18000 24000 30000 36000(600) (3800) (7500) (11200) (14900) (18600) (22400)

Pre-delivery


km (mi) covered


Check operation Every time vehicle is used

Brakes / Clutch Check operation ! ! ! ! ! ! ! !

Check lines for leakage ! ! ! ! ! ! ! !

Brake pads Check wear Every 1000 Km ( 600 mi )

( front and rear ) Check / Replace ! ! ! ! ! ! !

Fuel lines and connectionsCheck for leakage ! ! ! ! ! ! !

Replace At least every 3 years


Throttle control Check operation ! ! ! ! ! ! ! !

Check / Adjust play ! ! ! ! ! ! ! !

Choke control Check operation ! ! ! ! ! ! ! !

Flexible controls

and transmissionsCheck / Adjust ! ! ! ! ! ! ! !

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0 1000 6000 12000 18000 24000 30000 36000(600) (3800) (7500) (11200) (14900) (18600) (22400)

Pre-delivery


km (mi) covered


Check Every 1000 Km ( 600 mi )

Lubricate Every 1000 Km ( 600 mi ) and after riding under the rain

Drive chain Check / Adjust ! ! ! ! ! ! ! !

Lubricate ! ! ! !

Replace ! ! !

Check ! ! ! !

Front sprocket / Tab washerReplace

! ! !

Every time drive chain is replaced

Check ! ! ! !

Rear sprocketReplace

! ! !

Every time drive chain is replaced

Rear sprocket spring drive Check / Replace ! ! !

Steering head tube ring Check / Adjust ! ! ! !

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0 1000 6000 12000 18000 24000 30000 36000(600) (3800) (7500) (11200) (14900) (18600) (22400)

Pre-delivery


km (mi) covered


Steering bearingsCheck / Adjust ! ! ! !

Lubricate !

Check pressure Every time vehicle is used; at least every 10 days

TyresCheck wear Every time vehicle is used; at least every 500 Km ( 300 mi )

Check pressure ! ! ! ! ! ! ! !

Check wear ! ! ! ! ! ! !

Wheel rims Inspect visually! ! ! ! ! ! !

Every time tyre is replaced

Check! ! ! ! !

Front wheel bearings Every time tyre is replaced

Replace !

SidestandCheck operation Every time vehicle is used

Check operation ! ! ! ! ! ! ! !

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0 1000 6000 12000 18000 24000 30000 36000(600) (3800) (7500) (11200) (14900) (18600) (22400)

Pre-delivery


km (mi) covered


Lubricateneedle bearing

Lubricateneedle bearing

Side stand switchCheck operation Every time vehicle is used


Rear wheel hubCheck / ! !

Replace / !

Swingarm bearings Check / Lubricate !

Drive chain pads on swingarm Check / Replace ! ! ! ! ! ! !

Drive chain pads on frame plate Check / Replace ! ! ! ! ! ! !

Rear shock absorber Check / Adjust ! ! ! !

Front fork oil Renew !

Battery connections Check and clean ! ! ! ! ! ! !

Electrical equipment Check operation ! ! ! ! ! ! ! !

Instrument panelCheck operation Every time vehicle is used


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0 1000 6000 12000 18000 24000 30000 36000(600) (3800) (7500) (11200) (14900) (18600) (22400)

Pre-delivery


km (mi) covered


Check operation / Every time vehicle is used

Lights / Visual signalsReplace bulbsCheck operation /

! ! ! ! ! ! ! !Replace bulbs

HornCheck operation Every time vehicle is used



Headlight Check operation ! ! ! ! ! ! ! !

Adjust Every time geometry is changed

Ignition switchCheck operation Every time vehicle is used


LocksCheck operation Every time vehicle is used


Screws and nuts Check / Tighten ! ! ! ! ! ! ! !

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0 1000 6000 12000 18000 24000 30000 36000(600) (3800) (7500) (11200) (14900) (18600) (22400)

Pre-delivery


km (mi) covered


Hose clamps Check / Tighten ! ! ! ! ! ! ! !

General lubrication ! ! ! ! ! ! ! !

General test ! ! ! ! ! ! ! !

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1.3. Tools and accessories supplied

A bag in the glove compartment contains the followingtools:- 1 hexagonal bar (10 mm hexagon);- 6 Allen keys (2,5 - 3 - 4 - 5 - 6 - 8 mm hexagons);- 1 spanner for rear wheel eccentric with extension;- 1 fuse puller;- 3 fuses (15A).

The following accessories are also supplied:- 1 spark plug wrench (16 mm hexagon);- 1 document holder.

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Description Recommended product SpecificationsEngine lubrication oil AGIP RACING 4T 10W/60 (*) SAE 10W/60 - API SJ

Ethylene glycol dilutedCoolant AGIP ECO - PERMANENT with 50 percent

distilled waterBrake and clutch fluid AGIP BRAKE FLUID DOT4 DOT4Drive chain lubrication oil MOTUL CHAIN LUBE ROAD –

1.4. Table of lubricants and fluids

* : MV Agusta suggests to refer directly to its authorized dealers in order to purchase the recommendedproduct. The AGIP Racing 4T 10W/60 engine oil has been expressly produced for the F4 motorcycleengine. If the above described lubricant is not available, MV Agustasuggests to use a fully synthetic engine oil having characteristicsequal or better than the ones prescribed in the following standards:

– Consistent with: API SJ– Consistent with: ACEA A3– Consistent with: JASO MA– SAE Rating: SAE 20 W-50 o 10 W-60

NOTEThe above standard denominations must be written, alone ortogether, on the engine oil container label.

Engine oilSAE 10 W-60

API SJACEA A3JASO MA

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1.5. Removing/fitting the side fairing

Pull off the quick fastenings and then remove the sidefairing.

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Fit the side fairing, taking care to position the frontprofile as shown in figure A.Fasten the panel by positioning the tab in thelower part of the fairing as shown in figure B.

A B

Side fairing frontprofile

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1.6. Checking the engine oil level

Check the oil level while the engine is not running, andhas been allowed to cool down for at least ten minutesafter a ride.

The check must be performed after placing the motor-cycle in an upright position on a horizontal surface.

The level must be between the MAX and MIN marks onthe crankcase.If the oil level is below the MIN mark, top up asdescribed in § 1.6.1.

WARNINGDo not start the engine if the oil level is belowthe MIN mark.

Max

Min

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1.6.1. Topping up the engine oil level

Remove the oil filler plug by using the 10 mmhexagonal bar supplied, assembled on a properkey (see figure). Pour an appropriate amount ofengine oil of the recommended type. Never exceedthe MAX level mark. At the end of the operation,place back the oil filler plug and reassemble theright-hand side fairing.

WARNINGBefore reassembling the oil filler plug,grease its O-Ring by using AGIP Grease30.At last, perform the tightening of the oilfiller plug at the tightening torque of 35Nm, by using a dynamometric key.

CAUTIONTo avoid clutch sliding and damage tothe engine, never add chemical addi-tives to the engine oil, nor use an engineoil different from the one specified in thetable at § 1.4. Make sure that no foreignbody gets in the crankcase while top-ping up the engine oil.

Oil filler plug

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WARNINGNew or exhaust engine oil can be dan-gerous. Engine oil is highly toxic forpeople and domestic animals. Avoidingestion and contact. It has beenproved that prolonged contact withengine oil can cause skin cancer onguinea pigs. Even a brief contact withengine oil can cause skin irritation.• If the engine oil comes in touch withyour skin, wash it away with soap andwater.

• Keep new or exhaust engine oil out ofreach of children and domestic animals.• In the event of an engine oil ingestion,immediately call a doctor and do notcause vomiting, in order to avoid inhala-tion of engine oil in lungs.• While topping up the engine oil, weara long-sleeved shirt and a pair of water-proof gloves to protect your skin.• Correctly recycle or dispose of theexhaust engine oil, in order to avoidenvironmental pollution.

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1.7. Checking the coolant level

Check the coolant level while the engine is off and cold.The check must be performed after placing the motor-cycle in an upright position on a horizontal surface.

Ensure that the coolant level is between the MIN andMAX mark, as shown in the figure.

If the coolant level is below the MIN mark, top up thecoolant as described at paragraph 1.7.1.

WARNINGDo not start the engine if the coolant level isbelow the MIN mark.

MAX

MIN

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1.7.1. Topping up the coolant level

Remove the coolant filler cap and top upwith the recommended coolant (see§1.4).

WARNINGPerform the topping up of thecoolant when the engine is offand cold. Never attempt toremove the coolant filler capwhen the engine is hot, in orderto avoid the risk of burns. Thecooling system is under pres-sure!

After topping up, carefully replace thepreviously removed parts.

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WARNINGUnder certain conditions, ethylene gly-col contained in the coolant can becomeflammable. When it is lighted, it pro-duces an invisible flame.Avoid spilling coolant on hot parts ofthe motorcycle, because the subse-quent combustion of ethylene glycolcould cause serious burns.

WARNINGCoolant is a highly toxic fluid. Avoidcontact and ingestion. Keep coolant outof reach of children and domestic ani-mals. In the event of a coolant ingestion,immediately call a doctor and do notcause vomiting, in order to avoid inhala-tion of coolant in lungs. If the coolantcomes in touch with your skin or eyes,immediately wash it away with water.

CAUTIONTo top up the coolant level and/or renewthe coolant, use only the product speci-fied in the table in section 1.4. Do notmix nor dilute the coolant with additivesor different fluids. If the coolant speci-fied in section 1.4. is not available, use acoolant having technical characteristicsconsistent with the prescribed product.

CAUTIONCoolant can damage painted and plasticparts. When you top up the coolantlevel, be careful not to spill coolant onany part of the motorcycle. If you dospill coolant on your motorcycle, imme-diately wipe it away using a clean cloth.

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1.8. Checking the wear of the brake pads

Periodically check the width of the friction material layer of thepads, making sure it never falls below the wear limit (1 mm).

WARNING: If the brake pads are excessivelyworn out, the effectiveness of the brakingsystem decreases, increasing the risk of acci-dents. If the pads have worn to near the wearlimit, have both pads replaced by an autho-rized service centre. Ensure that the new padsare suitably broken in.

Front brake caliper Rear brake caliper

Disc

Pads

Wear limit 1 mm

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1.9. Checking the brake fluid level

WARNINGLack of maintenance of the braking sys-tem can increase the risk of accidents.Before riding, always check the brakingsystem according to the instructionsprovided in the Quick Manual.

The level of the brake fluid decreases as thebrake pads wear down. Ensure that the fluid levelis always between the MAX and MIN marks. If thelevel falls below the MIN mark, contact an autho-rized service centre and have the brake systemoverhauled.

Rear brake fluid reservoir

Max

Min

Front brake fluid reservoir

Max

Min

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WARNINGNever use your motorcycle if the fluidlevel is below the MIN mark. The brakesmay fail to properly operate, whichcould lead to an accident. If the brakefluid level is below the MIN mark, youmust have the braking system over-hauled by an authorized MV Agustadealer.

WARNINGHave the topping up of the brake fluidperformed only by skilled personnel.Brake fluid is highly toxic. Avoid contactand ingestion. Keep brake fluid out ofreach of children and domestic animals.In the event of a brake fluid ingestion,immediately call a doctor and do notcause vomiting, in order to avoid inhala-tion of brake fluid in lungs. If the brakefluid comes in touch with your skin oreyes, immediately wash with water.

WARNINGUse only the brake fluid specified atparagraph 1.4. of this manual. Mixing dif-ferent brake fluids can cause a dange-rous chemical reaction, as well as thedecrease of the braking efficiency, withsubsequent increase of the risk of acci-dents.

WARNINGAn insufficient amount of brake fluid mayallow the introduction of air in the brakingsystem. This could compromise the effec-tiveness of the braking system, with sub-sequent increase of the risk of accidents.Presence of air in the braking system canbe identified in the moment you feel acharacteristic “spongy effect” whilepushing the brake lever. In this case, havea braking system bleeding performed byan authorized MV Agusta dealer beforeriding your motorcycle again.

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1.10. Checking the clutch fluid level

The fluid level must be between the MAX and MINmarks.If the level falls below the MIN mark, contact an autho-rized service centre and have the clutch control systemrepaired.

WARNINGNever use your motorcycle if the fluid level isbelow the MIN mark. The clutch may fail toproperly operate, which could lead to an acci-dent. If the clutch fluid level is below the MINmark, have the clutch system overhauled byan authorized MV Agusta dealer.

WARNINGUse only the clutch fluid specified in the para-graph 1.4. of this manual.

MaxMin

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1.11. Checking and replacing the tyres

WARNINGBefore using the motorcycle,always check the pressure andwear of the tyres.

Checking the inflating pressure of thetyres is an essential requirement to ensu-re driving safety. Insufficiently inflatedtyres can reduce the handling of themotorcycle and wear themselves outvery quickly. On the other hand, anexcessively high inflating pressure redu-ces the wideness of the surface in con-tact with the ground, and it can compro-mise the grip of the vehicle.Before riding your motorcycle, it is the-refore necessary to measure the tyrepressure at room temperature. The vehi-cle must be parked since three hours atleast.

WARNINGAn incorrect inflating pressure can lead to dange-rous situations during riding. An insufficientlyinflated tyre can cause the sliding of the tyre onthe wheel rim or its detachment; this may lead tothe deflation of the tyre with subsequent loss ofcontrol of the vehicle.

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In fact, by checking the pressure soon afterwardsusing the motorcycle, you would obtain a highervalue than the actual one. This could cause anincorrect adjustment of the tyre pressure.Refer to the pressures given in § 3.2. and/or onthe label applied to the steering head tube. In theevent of long travels, you can increase the facevalue of the tyre pressure of 0.2 bar. In the eventof use of the motorcycle at a speed higher than300 km/h, increase the tyre pressure with refe-rence to the values given in § 3.2.

Moreover, it is extremely important to check thewear of the tyres before riding. In fact, a worn outtyre can be punctured more easily than a newone, and it can adversely affect handling and sta-bility of the motorcycle.Check that the depth of the tyre tread is not belowthe values prescribed by the Highway Code.Verify the absence of crevices at the bottom of thetread design and fissures on the tyre sidewall.Moreover, verify the absence of nails and glasssplinters in the tyre. If these conditions are not

verified, have the tyre replaced by an authorizedMV Agusta dealer.

WARNINGThe limits of the tyre tread depth mayvary from country to country. Alwaysrefer to the values prescribed by the lawprovisions of the nation in which youuse your motorcycle.

WARNING• If the tyres of your motorcycle areexcessively worn out, have it replacedby your MV Agusta dealer. Besidesbeing illegal, riding a motorcycle withexcessively worn out tyres can reduceits stability and lead to the loss of con-trol of the vehicle.• If a tyre is punctured it must bereplaced, not repaired. A repaired tyreprovides a restricted performance andlower safety levels than a new one. If

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you make a provisional or emergencyrepair to a tyre, you must ride at verylow speed until you reach the nearestMV Agusta dealer and have the tyrereplaced. With a provisionally repairedtyre, never exceed 60 km/h. Tyre repair-ing must never be performed if the tyreis punctured on its sidewall, or if thediameter of the puncture on the tread isgreater than 6 mm.• MV Agusta recommends not to usesealing fluids to repair a punctured tyre.These products can adversely affect thematerial of the tyre layers, as well ashide the minor damages caused byobjects penetrated in the tyre.

• When it is necessary to replace thetyres, use only the type specified inparagraph 3.2. Moreover, avoid usingtyres of a different brand or type on thefront and on the rear wheel at the sametime. Using tyres different from thosespecified can adversely affect the han-dling and stability of the motorcycle,increasing the risk of accidents.• The wheel rims of your motorcyclehave been designed for use with tube-less tyres only. Do not assemble an airtube tyre on rims designed for tubelesstyres. Otherwise, the tyre bead couldnot properly settle down on the wheelrim, leading to the deflation of the tyreand the loss of control of the vehicle.

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• Do not assemble an air tube on atubeless tyre. The overheating of thetyre could cause the explosion of the airtube, leading to the deflation of the tyreand the loss of control of the vehicle.• Have the tyres replaced according totheir direction of spin, which is high-lighted by a small arrow on the tyre side-wall.

• New tyres should be run in for a shortperiod before demanding their fullperformance. In fact, during this periodthe tyres could have a reduced grip onsome kind of roads. We suggest to rideat reduced speed and exercise extremecaution during the first 100 km after thereplacement of a tyre.

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" Rear wheel disassembling

CAUTIONIf you have the rear wheel tyrereplaced by a tyre-dealer, makesure that the following tools areused in the rear wheel disassem-bling and reassembling:• 55 mm polygonal socket wrench• Torque wrenchIf the above mentioned operationsare performed with tools other thanthose indicated, the rear wheelparts can be seriously damaged.Therefore, we strongly recommendnot to have the tyres replaced byan improperly equipped workshop.Always have the tyres replaced byan authorized MV Agusta dealer.

Wheel pin with M50x1.5 mmleft-hand pitch tread

Polygonal nut

55 mm polygonal socket wrench

Torque wrench

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" Checking the wheel rims

Before riding, always verify the absence ofcracks, bending or buckling on the wheel rims.

WARNINGIf you find that the wheel rim is dam-aged, have it replaced by an authorizedMV Agusta dealer. Never attempt torepair the wheel rim, even in case ofslight damage.Every time you replace a tyre or a rim,you must have a wheel balancing per-formed by an authorized MV Agustadealer. Wheel unbalance can adverselyaffect performance and handling of themotorcycle, as well as shorten the life ofthe tyres.

WARNINGWhen you have a wheel balancing per-formed, make sure to assemble onlyapproved counterweights on the wheelrim. MV Agusta recommends not to usebalancing or balancing/sealing fluids.

WARNINGDo not attempt to have a tubeless tyreremoved without using the proper toolsand protections for the wheel rim.Otherwise, you could damage the seal-ing surface of the rim, leading to thedeflation of the tyre and the loss of con-trol of the vehicle.

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1.12. Checking and lubricating the drive chain

To perform this operation, you must put the motorcycleon the rear stand, upright on a horizontal surface andwith the gear in neutral.

" Checking the chain adjustment

WARNING: Before checking the chain adjust-ment, contact a MV Agusta authorized centreto verify that the value of the static setup ofthe rear suspension is correct. Also makesure that the chain is properly lubricated.

The axis of the chain lower portion must be 50 mm fromthe lower chain guard. Manually turn the rear wheel andcarry out the check at several points along the chain. Thedistance between the chain and the lower chain guardmust remain almost constant as the wheel turns. If, onthe other hand, the play on the chain varies considerably,it means that some chain links are flattened, seized orelongated. If the distance is greater than 50 mm, havethe chain adjusted by your local MV Agusta dealer.

50 mm

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WARNINGRiding your motorcycle when the drivechain is in poor condition or improperlyadjusted can lead to accidents. Beforeriding, always check the chain adjust-ment according to the proceduresshown in this paragraph. If necessary,have the chain adjusted by your MVAgusta dealer.

WARNINGIf any chain link is flattened, seized orelongated, have the chain replaced by aMV Agusta authorized service centre.

WARNINGIf you notice damage or excessive wearof the chain and the correspondingsprockets, have them replaced by anauthorized MV Agusta dealer. Every timethe chain is replaced, you must alwaysreplace the front and rear sprockets too.

WARNINGUsing a chain with a fake link can bedangerous. An uncompletely riveted orfake link can accidentally split open andcause accidents, as well as damage tothe engine. Never use a chain with afake link.

WARNINGEvery time it is requested to operate therear wheel hub screws, contact anauthorized MV Agusta dealer. In order totighten the screws, apply a tighteningtorque equal to the value shown in thelabel placed on the swingarm. Applyinga torque higher than the indicated valuecan cause the fast decay of the rearwheel hub, compromising the reliabilityof the vehicle and the safety of the pilot.

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" Lubrication

To ensure proper operation, the drive chain needsto be properly lubricated.

Preliminary cleaning - Before lubrication, thedirt accumulated on the chain must be dissolvedusing kerosene. The dirt must then be removedwith a clean rag and/or an air jet.

CAUTIONThe chain is of the O-ring type. To pre-vent it from damaging, never clean thechain with a steam or high pressurewater jet, nor using gasoline or othersolvents. The chain must be cleanedusing kerosene only.

WARNINGKerosene is highly toxic and flammable.Avoid contact and inhalation. Keepkerosene away from sparks and flames.Keep kerosene out of reach of childrenand domestic animals. Correctly dispo-se of exhaust kerosene, in order toavoid environmental pollution.

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lubricant over the whole of the drive chain, takingcare not to smear the surrounding parts, and inparticular the tyres. Direct the lubricant jet on theinternal links, in order to lubricate the surface ofthe O-Rings and penetrate inside the chain roller.

CAUTIONOnly use the lubricant specified in theparagraph 1.4. of this manual, in orderto protect the drive chain and avoid oilspurts when the vehicle is in motion.

WARNINGChain lubrication must be performedaccording to the intervals specified inthe tables of scheduled maintenance(see § 1.2.). It is also necessary to per-form this operation after riding under therain and after cleaning the motorcycle.Riding your motorcycle when the drivechain is in poor condition or improperlyadjusted can lead to accidents.

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1.13. Checking the idle speed

Check the idle speed when the engine has reached theoperating temperature. Ensure that the choke controlhas not been activated.

The idle speed should range from 1,150 to 1,250 rpm.

If a tune-up is necessary, contact an authorized servicecentre.

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1.14. Replacing parts - General information

The replacement of the fuses and the light bulbs(excepting the front parking light bulbs) can becarried out by the owner according to the indica-tions provided below.

1.14.1.Replacing the fuses

The battery recharge fuse is located on thesolenoid starter of the motorcycle. To expose it,remove the rider’s saddle.

Solenoidstarter

Battery recharge fuse

Service fuses

Headlight - Replacement

License plate light bulb - Replacement

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GB Spare fuse (40 A)Recharge fuse (40 A)

CAUTIONTurn the ignition key on the “OFF” posi-tion before checking or replacing thefuses, in order to avoid a short circuitwith subsequent damage to other elec-tric parts of the motorcycle.

To replace the fuse, you must swap the rechar-ge fuse with the spare fuse.

WARNINGNever replace a fuse with a rating otherthan that precribed, in order to avoiddamage to the electrical equipment ofthe motorcycle which could lead to a fire.

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MAINTENANCE 1

1 GBThe service fuses are located on the left side.

To expose them, remove the side fairing (see§1.5.).

Release the two clamps and lift the fuse boxcover.

CAUTIONTurn the ignition key on the “OFF” posi-tion before checking or replacing thefuses, in order to avoid a short circuitwith subsequent damage to other elec-tric parts of the motorcycle.

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MAINTENANCE 1

1

GB

Replace the blown fuse and refit the cover.

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MAINTENANCE 1

1 GB

15A

15A

15A

F1 F2 F3 F4 F5 F6 F7

15A

15A

15A

15A

To identify the position and function of thefuses, refer to the information shown in theenclosed electrical diagram. The reference lettersin the figure correspond to those shown in the dia-gram.Remember that the tool bag contains three sparefuses.

WARNINGNever replace a fuse with a rating otherthan that precribed, in order to avoiddamage to the electrical equipment ofthe motorcycle which could lead to a fire.

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MAINTENANCE 1

1

GB

1.14.2.Replacing the license plate light bulb

Remove the fixing screws of the lower cover of thelicense plate holder.

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MAINTENANCE 1

1 GBRemove the lower cover.

Extract the bulb socket sliding it from its seat.

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MAINTENANCE 1

1

GB

Extract the bulb.Insert the new bulb.Reposition the bulb socket.

Reassemble the lower cover of the license plate holder.

Caution: Before reassembling pay specialattention to positioning the tail light harnesscorrectly, in order to avoid any damage (seefigure).

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MAINTENANCE 1

1 GB

1.15. Battery

The battery is of the maintenance-free type and isinstalled under the tail section. This battery doesnot require checking of the fluid level or adding ofdistilled water.If the battery seems to be run-down (causing elec-trical problems or a difficult starting), have itrecharged by an authorized MV Agusta dealer assoon as possible. Remember that the battery runsdown more quickly if your motorcycle is equippedwith additive electrical accessories.

WARNINGIf the battery casing is damaged, theremay be a leakage of sulphuric acid, aHIGHLY TOXIC AND CORROSIVE sub-stance. Avoid any contact with youreyes, skin and clothes. Always wearprotective glasses when you have towork near the battery.

In the event of a contact with sulphuricacid, give the FIRST AID as describedbelow:• CONTACT WITH EYES: Wash awaywith water for about 15 minutes, andimmediately call a doctor.• CONTACT WITH SKIN: Wash awaywith a great amount of water.• INGESTION: Drink great amounts ofwater or milk, and immediately call adoctor.Furthermore, leakage of sulphuric acidcan result in the formation of hydrogengas which, if ignited by a spark or aflame, would cause an explosion.Always have the battery replaced byyour local MV Agusta dealer.

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MAINTENANCE 1

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GB

Prolonged inactivity

If the motorcycle is to remain unused for a longtime (a month or longer), it is advisable to discon-nect the battery cables or have the batteryremoved by skilled personnel. In case of pro-longed inactivity, to avoid shortening the life of thebattery, it is essential to have it recharged by yourMV Agusta dealer every 4-5 months.

WARNING: The inversion of the batterywires can damage the battery and therecharging system. The red wire mustbe connected to the positive terminal(+), while the black wires must be con-nected to the negative terminal (-).When removing the battery, disconnectthe negative terminal FIRST and thenthe positive terminal. When reinstallingthe battery, use the reverse procedure.

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MAINTENANCE 1

1 GB

1.16. Cleaning the motorcycle

Periodic careful cleaning is a key fac-tor in preserving the value of themotorcycle, protecting its surface fin-ish and checking for damages, wearand leakage of corrosive fluids.

CAUTION: Before washingthe vehicle, stop up theexhaust pipes and protectthe electrical parts.

WARNING: Do not wash yourmotorcycle soon afterwards rid-ing. Attend a few minutes toallow the engine and the exhaustpipes to thoroughly cool.

INFORMATION: Spilling deter-gent can cause environmen-tal pollution. Therefore, youshould clean your motorcyclein an area equipped for col-lection and disposal of wash-ing fluids.

CAUTION: Never use washing systems involvingsteam or high pressure water jets. These systemscould cause water infiltration and damage the inter-nal parts of your motorcycle.

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MAINTENANCE 1

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GB

Wash the motorcycle with water, a mild detergentand a sponge. Wipe the vehicle with a soft cloth.Use an air jet to dry difficult-to-reach areas.

CAUTION• Avoid using clothes or sponges thathave been in contact with strong orabrasive detergents, solvents or gaso-line.• To avoid irreparable damage to thefairing, never use alkaline or stronglyacid detergents, petrol, brake fluid orother solvents. Clean the fairing onlywith a soft cloth, warm water and a neu-tral detergent.• If you have doubts about the chemicalcomposition of the detergent, test itseffect by applying it on a little area of thefairing before using it on the whole bike.

Periodically treat the paintwork with high qualitywax. After riding on roads treated with corrosivesubstances (salt), wash the vehicle as soon as

possible with cold water. Do not use hot water asit enhances the corrosive action.

WARNING: Avoid smearing brakes ortyres with oil or wax. If necessary, cleanthe brake discs with a brake disc deter-gent or with acetone, and wash the tyreswith warm water and a neutral detergent.

WARNING: The presence of water on thebrakes can lead to a decrease of thebraking effectiveness with subsequentrisk of accidents. After completing thewashing, run the engine for a few min-utes and start off at reduced speed.Carefully apply the brakes a few times soas to dry the brake pads and discs.

WARNING: The drive chain must be cor-rectly lubricated after washing themotorcycle, following the instructionsprovided at § 1.12. of this manual.

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MAINTENANCE 1

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1.17. Prolonged inactivity

If the motorcycle is to remain unused for a long time, it isadvisable to carry out the following operations:

When the motorcycle is first put back into service, rememberto carry out a comprehensive check and, if necessary, to havethe vehicle serviced (§1.2.).

Empty the fuel tank.

Remove the battery and store it in a suitable place.

Remove the spark plug caps and the spark plugs. Pour a teaspoonful of engine oil in every sparkplug hole, then place back the spark plugs and the corresponding caps. Make the engine run idlefor a few times.

Lubricate all control cables and the joints of all pedals and levers.

Clean the motorcycle and treat the paintwork with high quality wax (§ 1.16).

In order to ensure integrity and performance of the tyres, park your motorcycle in a fresh, dry anddark place, with a temperature relatively constant and lower than 25° C. Avoid direct contact of thetyres with heating pipes or radiators, and prolonged contact with oil or gasoline. Avoid parking withthe tyres near to electrical motors or devices capable to produce sparks or electric discharge.During the period of inactivity, place your motorcycle on the rear stand.

Cover the vehicle with an adequate canvas cover.

TROUBLESHOOTING FLOW CHART 2

2

GB

2.1. Engine problems: ENGINE DOES NOT START

Problem solved

Problem solved

Problem solved

Engine stop switchdepressed

Gears engaged andside stand down

Starting procedurecorrectly performed

Disengage gears orlift stand and pull

clutch lever

Return the engine stopswitch in rest position

Correctly performstarting procedure

Engine starts

Engine starts

Engine starts

NO

YES

NO

YES

YES

NO

YES

YES

YES

NO

NO

NO

continued on next page

Problem solvedFuel tank empty Refuel Engine starts

NO

YES YES

NO

- 52 -

- 53 -


2 GB

Problem solvedFuses F4 and F6are OK

Replace fuses F4 and F6(§1.14.1.)

Contact a MV Agustaauthorized service centre

Engine starts

YES

NO YES

Problem solvedThe battery ischarged

Have the battery rechar-ged by a MV Agusta

authorized service centreEngine starts

YES

NO YES

NO

NO

continued from previous page

YES

Problem solvedThe key code hasbeen recognized

Insert the code printed on the MV Code Card

by a MV Agustaauthorized service centre

Engine startsNO YES

NO

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2

GB

Problem solved

The dashboardis on

Fuel tank empty Refuel



Engine is running

YES

NO

YES

NO YES

Problem solvedFuses F4 and F6

are OKReplace fuses F4 and F6

(§1.14.1.)Engine is running

NO

NO YES

NO

NO

ENGINE SHUTS OFF DURING RIDING

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2 GB

Problem solved

Coolant level iscorrect (§1.7.)

Fuse F5is OK

Replace fuse F5(§1.14.1.)



Engine coolsdown to operating

temperature

YES

NO

YES

NO YES

NO

ENGINE OVERHEATS

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2

GB

OIL PRESSURE IS TOO LOW (Engine oil pressure warning light is on with the engine running)

Oil level is correct(§1.6.)


Have the oil level resto-red by a MV Agusta

authorized service centre

Oil pressure isoptimal

YES

NO YESProblem solved

NO

- 57 -


2 GB

Problem solved

Problem solvedThe fuses of thelighting are OK

Bulbs are OKReplace bulb(s)

(§1.14.)

Replace fuse(s)(§1.14.1.)


Lights work

Lights work

YES

NO

YES

NO

YES

YES

NO

NO

2.2. Electrical equipment problems: LIGHTS DO NOT WORK

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2

GB

HORN DOES NOT WORK

Fuse F1is OK


Replace fuse F1(§1.14.1.) Horn works

YES


NO

Fuse F1is OK



Speedometerworks

YES


NO

SPEEDOMETER DOES NOT WORK


2 GB

DASHBOARD WARNING LIGHTS DO NOT WORK

Fuse F1is OK



YES

NO

NO

ALTERNATOR DOES NOT CHARGE BATTERY (Battery charge indicator is on with the engine running)

Problem solvedWarning lightswork

Battery rechargefuse is OK


Replace batteryrecharge fuse

(§1.14.1.)

Alternatorcharges battery

YES


NO

YES

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TECHNICAL INFORMATION 3

3

GB

3.1. Motorcycle overview

(N) Instrument panel

(B) Ignition - Power supply

(F) Frame

(D) Final drive

(E) Cooling system

(G) Front suspension

(L) Front brake

(A) Engine

(C) Gearbox

(H) Rear suspension

(O) Exhaust system

(M) Rear brake

(I) Battery

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3 GB

A - Engine: four-stroke, inline four-cylinder.Double-overhead camshaft valve train withradial valves. Wet sump lubrication.

B - Ignition - Power supply: integrated ignition-injection system. Inductive-discharge electro-nic ignition. “Multipoint” electronic injection.

C - Gearbox: removable, six-speed, with con-stant-mesh gears.

D - Final drive: consisting of drive sprocket, rearsprocket and chain.

E - Cooling system: with separate liquid and oilradiators.

F - Frame: tubular steel trellis with aluminiumside plates.

G - Front suspension: upside-down hydraulicfork with external adjusting system.

H - Rear suspension: progressive, with single-sided swingarm and single shock absorberwith external adjusting system.

I - Battery: sealed and maintenance-free.

L - Front brake: dual semi-floating disc withfour-piston calipers.

M - Rear brake: single disc with four-piston cali-per.

N - Instrument panel: with warning lights anddigital instruments.

O - Exhaust system: equipped with catalyticconverter for exhaust emission reduction.

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GB

3.1.1 Front brake circuit

1 Brake master cylinder2 Brake lever3 Brake line4 Brake caliper5 Brake discs

12

3

4

5

4

5

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3 GB

3.1.2. Rear brake circuit

1 Brake lever2 Brake master cylinder3 Brake line4 Brake fluid reservoir5 Brake caliper6 Brake disc

4

6

1 2

3

5

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3

GB

3.1.3. Clutch circuit

1 Clutch lever2 Clutch master cylinder3 Clutch line4 Clutch cylinder assembly

2

1

3 4

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3 GB

3.1.4. Engine lubrication

1 Oil sump2 Oil filter3 Cylinder head oil feed pipe

3

1 2

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3

GB

3.1.5. Coolant circuit

1 Expansion tank2 Upper radiator3 Lower radiator4 Coolant pump

3 4

12

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3 GB

3.1.6. Fuel system

1 Throttle bodies2 Fuel pump3 Fuel line

2

3

1


3

GB

Description F4 1000SPECIFICATIONSWheelbase (mm) (*) 1430Overall length (mm) (*) 2100Max. width (mm) 750Seat height (mm) (*) 830Min. ground clearance (mm) (*) 115Trail (mm) (*) 100,4

3.2. Specifications

* : The indicated values must not be intended as binding informations. They can change according to the vehicle setup.

2100

1430

115

830

750

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3 GB

Description F4 1000Dry weight (Kg) 192 Fuel tank capacity (lt) (*) 17Reserve fuel (lt) (*) 4Oil in crankcase (lt) 3,5ENGINEType Four-cylinder, four-stroke, 16 valvesBore (mm) 76Stroke (mm) 55Total displacement (cm3) 998Compression ratio 13,1 : 1Starting Electric starterCooling system Cooling with separate liquid and oil radiatorsCrankcase and covers Die-castHead and cylinders Chill-castValves Bimetal / single-metalVALVE TRAINType Double-overhead camshaft, radial valves

Specifications

* : The indicated data must not be intended as binding informations. They can change according to the environmental tempe-rature, the engine temperature and the evaporation point of the gasoline.

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GB

- 70 -

Specifications

Description F4 1000LUBRICATIONType Wet sumpIGNITION - POWER SUPPLYType “Magneti-Marelli” IAW 7BM integrated ignition-injection system

with Mikuni throttle body; inductive discharge electronic ignition;“Multipoint” phased sequential electronic injection;

variable lenght intake funnel with Torque Shift System (TSS)Spark plugs NGK CR9 EBSpark gap (mm) 0,7 ÷ 0,8CLUTCHType Multiple-disc in oil bath with mechanical anti-surging devicePRIMARY DRIVENumber of teeth on crankshaft gear Z = 50Number of teeth on clutch gear Z = 79Transmission ratio 1,58SECONDARY DRIVENumber of teeth on front sprocket Z = 15Number of teeth on rear sprocket Z = 41Transmission ratio 2,73TRANSMISSIONType Removable, six-speed gearbox with constant-mesh gears


3 GB

Specifications

Description F4 1000Gear ratio (overall ratios)First gear 2.92 (12.60)Second gear 2.12 (9.14)Third gear 1.78 (7.68)Fourth gear 1.50 (6.47)Fifth gear 1.32 (5.69)Sixth gear 1.21 (5.22)FRAME Type CrMo steel tubular trellis (TIG welded)Swingarm pivot plates Aluminium alloyFRONT SUSPENSIONType “Upside down” telescopic hydraulic fork with external and separated

adjustment of rebound and compression damping and of spring preloadRod diameter (mm) 50Travel on leg axis (mm) 120REAR SUSPENSIONType Progressive, single shock absorber with rebound-compression

(high speed/low speed) damping and spring preload adjustmentSwingarm Aluminium alloyWheel travel (mm) 120

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3

GB

Specifications

Description F4 1000

FRONT BRAKE

Type Double steel floating disc

Disc diameter (mm) 320

Disc flange Aluminium

Calipers, piston diameters (mm) Radial-type, single-piece with 4 pistons (Ø 34)

REAR BRAKE

Type Single steel disc

Disc diameter (mm) 210

Caliper, piston diameter (mm) 4-piston (Ø 25.4)

FRONT RIM

Material Forged aluminium alloy

Dimensions 3,50” x 17”

REAR RIM

Material Forged aluminium alloy

Dimensions 6,00” x 17”

TYRES

Front 120/70-ZR 17 (58 W)

Rear 190/55-ZR 17 (75 W)

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3 GB

Specifications

* : If you use tyres of a brand different from the ones recommended, refer to the inflating pressure values marked by the manu-facturer on the tyre sidewall.

Description F4 1000Brand and type PIRELLI - Diablo Supercorsa SP

DUNLOP - Sportmax Qualifier RRInflating pressure (*) At a speed lower than 300 km/h At a speed higher than 300 km/hFront PIRELLI: 2.3 bar (33 psi) 2.5 bar (36 psi)

DUNLOP: 2.3 bar (33 psi) 2.5 bar (36 psi)Rear PIRELLI: 2.3 bar (33 psi) 2.9 bar (42 psi)

DUNLOP: 2.3 bar (33 psi) 2.9 bar (42 psi)ELECTRICAL EQUIPMENT Equipment voltage 12VHeadlight bulb OSRAM Xenarc D1S 35WTail light bulb 12V 5WBattery 12V - 8,6 AhAlternator 350 W at 5000 rpmBODYWORKFairing Thermoplastic materialFront fairing Thermoplastic materialTail section Thermoplastic materialFuel tank Thermoplastic material

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3

GB

Specifications

Description F4 1000Air scoops Thermoplastic materialAir box Thermoplastic materialAir box side panels Thermoplastic materialFront mudguard Thermoplastic materialChain guards Thermoplastic materialExhaust pipe guard AluminiumHeat shield Thermoplastic materialLicense-plate holder Thermoplastic material

- 75 -


3 GB


3

GB

23 45

7

12

9

108

6

1

11

- 76 -

- 77 -


3 GB

8. - Left-hand side fairing;9. - Right-hand side fairing;10. - Undercowl;11. - Fuel tank left-hand side fairing;12. - Fuel tank right-hand side fairing:

Colour code A: Metalized silver(Code Palinal 928XV025)Colour code B: Matt Black(Code Palinal 929XR486 + Palinal Matt 3)Colour code C: Admiral grey(Code Palinal L820)

3.3. Bodywork parts reference coloursBodywork parts are painted with the following reference colours, according to the correspondingmotorcycle colour combination:

1. - Front fairing;2. - Left-hand rearview mirror;3. - Right-hand rearview mirror;4. - Air box;5. - Fuel tank;6. - Rear left side panel;7. - Rear right side panel:

Colour code A: Crayon red(Code Palinal 926R750)Colour code B:Shiny black(Code Palinal 929R486H)Colour code C:Titanium grey(Code Palinal L821)


3

GB

2

3

1

4

- 78 -

- 79 -


3 GB

3.4. Frame parts reference colours

Frame parts are painted with the following reference colours:

1. - Frame:Colour code A-B:Metal Antracite grey(Code Palinal 926XH893)Colour code C:Frame red(Code Palinal 211XH987)

3. - Engine:Matt black(Code Pulverit 3500/0085)

4. - Engine head cover:Frame red(Code Palinal 211XH987)

2. - Headlight holder:Metal Antracite grey(Code Palinal 926XH893)

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3

GB

NOTES

© 2009This document may not, in whole or in part, be reproduced without prior consent, in writing, from MV Agusta S.p.A.

Part No. 8000B4299Edition No. 1 - December 2009

Information

MV Agusta S.p.A. is committed to a policy of constant improvement; therefore, you may find slight differen-ces between the information provided in this document and the vehicle you purchased. MV Agusta motorcy-cles are exported in several countries, in which different rules and regulations (concerning both theHighway Code and the homologation procedures) are in force. Relying on your understanding, MV AgustaS.p.A. deems it necessary to reserve the right to change its products and the related documentation at anytime and without notice.

We suggest to often visit the Internet site www.mvagusta.it in order to obtain informations and updatesabout the MV Agusta products and the related documentation.

Respect and defend natural environment

Everything we do affects the whole planet as well as its resources.MV Agusta, in order to protect the interests of the community, awakens the Customers and the TechnicalAssistance operators to use the vehicle and dispose of its replaced parts respecting the laws in force con-cerning environmental pollution and waste disposal and recycling.

http://www.mvagusta.it

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