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Documenti di Professioni
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This manual, to be used by the MV Agusta authorised workshops has been realised with the
purpose of assisting authorised personnel in maintenance and repairs operations of the
motorcycle. The knowledge of technical data herein noted, determines the complete profes-
sional training of the technician.
With purpose of making the reading of this manual immediately comprehensible, the para-
graphs have been aligned with detailed illustrations that highlight the argument dealt with.
Useful advice
To prevent any problems and to reach an excellent final result, MV Agusta recommends
keeping to the following guidelines:
- In the case of an eventual repair, evaluate the client’s impressions who states that there
is an abnormal functioning of the motorcycle and to formulate the right questions to
clarify the symptoms of the problem.
- Clearly diagnose the cause of the abnormality. The basic fundamental theories can be
absorbed by reading this manual that must necessarily be integrated to the personal
experience and the participation of training courses that are periodically organised by
MV Agusta.
- Rationally plan the repair to avoid slack periods, 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
this reason, there could be slight differences between that which is written here and the
motorcycle on which repairs and/or maintenance are about to be carried out. MV Agusta
models are exported to many countries where different norms in relation to the highway
code and homologation procedures are valid. Hoping that you will comprehend these prob-
lems, MV Agusta S.p.A. reserves the right to make modifications to its products and tech-
nical documentation at any moment and without prior announcement.
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Freni
General Index
GENERAL DESCRIPTION........................................................................................ A
Rev. 0
MAINTENANCE ........................................................................................................ B
Rev. 3
BODYWORK ............................................................................................................ C
Rev. 1
FRAME ...................................................................................................................... G
Rev. 2
BRAKES.................................................................................................................... H
Rev. 2
DIAGNOSTICS .......................................................................................................... O
Rev. 0
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General description
SECTION
Revision 0
A
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General description
A SUMMARY
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General description
EXAMPLE
Steering pin tightening
10°
Screw in the steering pin flange ring, without tighten- 2
ing.
This operation must be done manually.
Check that the steering base is at the end of its travel,
to the right.
Using the special tool N. 800091645, tighten the ring
(1) by rotating it 10° calculated approximately as one
third of the movement between the two holes of the
ring (2) of the steering head (see the figure).
MV Agusta S.p.A. is committed to a policy of continuous updating of the models produced. The modifications and
significant changes to the specifications and the procedures will be communicated to the official dealers and will
appear in future editions of this manual.
All information, instructions and technical data included in this manual are based upon information on the prod-
uct updated at the moment of going to print. MV Agusta S.p.A. reserves the right to carry out changes at any
moment without prior notice and without incurring any obligation.
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General description
NOTE Supplies key information for the best fulfil- Use the recommended thread-locking
ment of the operation. fluid.
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General description
Cylinder 3 Cylinder 2
Cylinder 4 Cylinder 1
Left side
Right side
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General description
A SAFETY
The information contained in this paragraph is fundamental so that the operations carried
ATTENTION
out on the motorcycle can be conducted with minimum risk to the mechanic.
Carbon Monoxide
• Exhaust gases contain carbon monoxide (CO) that is poisonous. Carbon monoxide can cause the loss of con-
sciousness and death.
• If it is necessary to switch on the engine, check that the environment is well ventilated. Never switch on the engine
in an enclosed environment.
• Switching on the engine can only be carried out in an enclosed environment when there are the appropriate devices
for the evacuation of exhaust gases.
Petrol
• Petrol is extremely inflammable and under certain conditions can be explosive.
• Keep sources of heat, sparks and flames away from the work area.
• Always work in a well-ventilated area.
• Never use petrol as a cleaning solvent. Generally, avoid handling it unless it is absolutely necessary.
• Do not use petrol for cleaning components by using compressed air.
• Keep petrol out of reach of children.
Engine oil
• Engine oil can cause skin illnesses if in constant and long contact with the skin.
• If the skin comes into contact with engine oil, wash the parts affected as soon as possible with soap and water.
• If engine oil comes into contact with the eyes, abundantly rinse with water and consult a doctor immediately.
• If engine oil is swallowed, do not provocate vomiting to avoid the aspiration of the product into the lungs. Transport
the injured person immediately to hospital.
• Used oil contains dangerous substances and poisonous for the environment. To substitute oil, it is recommended to
go to an authorised MV Agusta dealer who is equipped to deal with the collection of used oil in respect of the norms
in force.
• Do not dispose of used oil in 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 coolant.
• The engine coolant (ethylene glycol) can cause irritation of the skin and is poisonous if swallowed.
• If the engine coolant comes into contact with the skin, immediately remove any contaminated clothing and wash with
soap and water. If it comes into contact with the eyes, abundantly rinse with clean water and immediately consult a
doctor. If swallowed, do not provocate vomiting to avoid the aspiration of the product into the lungs. Administer clean
water and transport the injured person immediately to hospital and show the product to the doctor.
• If exposed to high concentrations of vapour, transport the injured person to a non-poisonous atmosphere and if nec-
essary call a doctor.
• Do not remove the radiator cap when the engine is still hot. Being under pressure, the engine coolant can be vio-
lently ejected and therefore provocate burns.
• The engine coolant contains dangerous and poisonous substances and is therefore dangerous for the environment.
To substitute used engine coolant, it is advisable to go to the authorised MV Agusta dealer who is equipped to deal
with the collection of used engine coolant in respect of the norms in force.
• Do not dispose of engine coolant in the environment.
• Keep engine coolant out of reach of children.
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General description
Brake fluid
A
• Brake fluid is extremely corrosive.
• Avoid any contacts with the eyes, skin and the mucous membrane.
• If brake liquid comes into contact with the skin, remove all contaminated clothing and wash immediately with soap
and water.
• If brake fluid comes into contact with the eyes, abundantly rinse with water and call a doctor.
• If swallowed, do not provocate vomiting to avoid aspiration of the product into the lungs. Immediately call a doctor.
• Take the injured person immediately to hospital, if he has breathed brake fluid into the lungs.
• In the case of exposure to high concentrations of vapour, move the injured person to a non-poisonous atmosphere
and if necessary call a doctor.
• In the case of accidental contact, rinse abundantly with water and call a doctor.
• Keep brake fluid out of reach of children.
Thread-locking fluid
• As it is not classified as dangerous, the prolonged contact with the skin, particularly with regards to abrasions can
provocate sensitiveness and dermatitis. In the case of contact with the skin, rinse abundantly with running water.
• Move the injured person into the open air and call a doctor if the injured person feels ill after having breathed in the
product.
• In the case of contact with the eyes, rinse abundantly with water for at least 15 minutes.
• If the thread-locking fluid has been swallowed, drink an abundant quantity of water or milk. Do not provocate vomit-
ing to avoid the aspiration of the product into the lungs. Immediately call a doctor.
• Keep out of reach of children.
Battery
• The battery produces explosive gases. Keep it away from sparks, flames or cigarettes. During recharging, ade-
quately ventilate the environment.
• The battery contains a solution of sulphuric acid (electrolyte).
• Sulphuric acid is corrosive and it destroys many materials and clothing. On contact with small quantities of water it
generates a violent reaction that manifests itself by creating large quantity of heat and spurts of hot acid. Sulphuric
acid attacks many metals thereby liberating hydrogen: an inflammable gas that forms an explosive mixture when
mixed with air.
• Contact with sulphuric acid can cause burns. In the case of contact, remove immediately all contaminated clothing
and wash the skin with abundant quantities of water. Take the injured person to hospital if necessary.
• In the case of contact with the eyes, rinse immediately with abundant water. Call a doctor and continue with the treat-
ment until the doctor arrives.
• If the electrolyte is swallowed, rinse the mouth with water without swallowing. Take the injured person immediately
to hospital and explain to the doctor there what the injured person has swallowed.
• The battery contains dangerous substances that are poisonous for the environment. It is advisable to substitute it at
an MV Agusta dealer that is equipped to dispose of this product in respect of the norms in force.
• Do not dispose of used batteries in the environment.
• Keep out of reach of children.
Hot parts
• The engine and the exhaust system become very hot and maintain this temperature for some time after the engine
has been switched off. Wait for these parts to cool down before handling them or working on the motorcycle near to
them. Use protective gloves.
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General description
A WARNING
The information contained in this
WARNING paragraph is important so that the
operations carried out on the motor-
cycle can be conducted without damaging the motorcycle.
• Thoroughly clean the motorcycle before disassembling it.
• During disassembly, clean all parts and 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.
• Slackening or tightening nuts or screws, always start with
those of a greater dimension or from the centre. Always
respect the torque values indicated.
• Utilise only MV Agusta spare parts.
INDEX
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General description
The registration number of the motorcycle is stamped on the right side of the steering head.
The engine registration number is stamped on the upper engine casing, near the forks.
ZCG F6 10 AA Y V 000000
Manufacturer identification
Vehicle model
Progressive frame number
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General description
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Maintenance
SECTION
Revision 3
B
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Maintenance
SUMMARY
B
TECHNICAL DATA (MY10 -> MY12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 3
TECHNICAL DATA (MY13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 5
PERIODICAL MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 7
MAINTENANCE AND TUNING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 9
ENGINE OIL AND OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 9
ENGINE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 13
ELECTRIC COOLING FANS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 15
VALVE MECHANISM ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 16
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 26
FUEL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 28
FUEL PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 34
TUBES / FUEL FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 37
FUEL TUBE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 37
THROTTLE BODY ADJUSTMENT AND CALIBRATION (MY10 -> MY12) . . . . . . . . . . . . . . . . . . . . . .PAGE 38
THROTTLE BODY ADJUSTMENT AND CALIBRATION (MY13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 41
AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 44
BRAKES AND CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 49
BRAKE / CLUTCH / GEARCHANGE COMMANDS CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 52
BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 54
THROTTLE CONTROL (MY10 -> MY12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 55
LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 56
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 58
TRANSMISSION CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 58
TYRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 61
FRONT WHEEL BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 61
WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 62
REAR WHEEL HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 62
SWINGARM BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 62
REAR SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 63
SIDE STAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 64
FRONT FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 65
NUTS AND BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 65
TUBE FASTENING BANDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 65
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 65
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 65
WARNING LIGHTS AND INSTRUMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 66
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 99
FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 104
FRONT HEADLIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 107
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Maintenance
TECHNICAL INFORMATION
* : The data declared are not binding. They are susceptible to variations due to riding conditions.
** : The data declared are not binding. They are susceptible to variations due to external temperature, engine temperature and the evaporation point of the petrol used.
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Maintenance
B
LUBRICATION
Type Wet sump
IGNITION - FUEL FEED SYSTEM
Type “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 EB NGK CR9 EB NGK CR9 EB NGK CR9 EB
Spark gap (mm) 0.7 ÷ 0.8 0.7 ÷ 0.8 0.7 ÷ 0.8 0.7 ÷ 0.8
CLUTCH
Type Multiple-disc in oil bath with mechanical anti-surging device
PRIMARY DRIVE
N° teeth - engine crankshaft Z = 50 Z = 50 Z = 48 Z = 48
N° teeth - clutch gear Z = 79 Z = 79 Z = 82 Z = 82
Transmission ratio 1.58 1.58 1.708 1.708
SECONDARY DRIVE
N° teeth - pinion wheel Z = 15 Z = 15 Z = 15 Z = 15
N° teeth - crown wheel Z = 41 Z = 41 Z = 41 Z = 41
Transmission ratio 2.733 2.733 2.733 2.733
TRANSMISSION
Type Removable, six-speed gearbox with constant-mesh gears
Gear ratios (total ratios)
1st 2.64 (11.39) 2.64 (11.39) 2.643 (12.341) 2.643 (12.341
2nd 2.06 (8.88) 2.06 (8.88) 2.062 (9.631) 2.062 (9.631)
3rd 1.72 (7.42) 1.72 (7.42) 1.722 (8.042) 1.722 (8.042)
4th 1.50 (6.47) 1.50 (6.47) 1.500 (7.004) 1.500 (7.004)
5th 1.32 (5.69) 1.32 (5.69) 1.318 (6.155) 1.318 (6.155)
6th 1.19 (5.13) 1.19 (5.13) 1.190 (5.559) 1.190 (5.559)
FRAME
Type CrMo steel tubular CrMo steel tubular CrMo steel tubular CrMo steel tubular
trellis (TIG welded) trellis (TIG welded) trellis (MAG welded) trellis (TIG welded)
Swingarm pivot plates Aluminium alloy Aluminium alloy Aluminium alloy Aluminium alloy
FRONT SUSPENSION
Type “Upside down” telescopic “Upside down” telescopic “Upside down” telescopic öHlINS Nix30 - “Upside down”
hydraulic fork with external hydraulic fork with external hydraulic fork with external telescopic hydraulic fork with
and separated adjustment of and separated adjustment of and separated adjustment of external and separated adjustment
rebound and compression rebound and compression rebound and compression of rebound and compression
damping and of spring preload damping and of spring preload damping and of spring preload damping and of spring preload
Ø stems (mm) 50 50 50 50
Travel on leg axis (mm) 120 120 120 120
REAR SUSPENSION
Type Progressive, single shock Progressive, single shock Progressive, single shock öHlINS TTx - Progressive,
absorber with rebound-com- absorber with rebound-com- absorber with rebound-com- single shock absorber with
pression (high /low speed) damping pression (high /low speed) damping pression (high /low speed) damping rebound-compression damping
and spring preload adjustment and spring preload adjustment and spring preload adjustment and spring preload adjustment
Wheel travel (mm) 120 120 120 120
Swingarm Aluminium alloy Aluminium alloy Aluminium alloy Aluminium alloy
FRONT BRAKE
Type Dual floating disc with Dual floating disc with Dual floating disc with Dual floating disc with
steel braking band steel braking band steel braking band steel braking band
Ø discs (mm) 320 320 320 320
Disc flanges Aluminium Aluminium Aluminium Aluminium
Master cylinder Axial-type Axial-type Axial-type Radial-type
Calipers (Ø pistons mm) Radial-type, single-piece Radial-type, single-piece Radial-type, single-piece Radial-type, single-piece
with 4 pistons (Ø 34) with 4 pistons (Ø 34) with 4 pistons (Ø 34) with 4 pistons (Ø 34)
REAR BRAKE
Type Single steel disc Single steel disc Single steel disc Single steel disc
Ø disc (mm) 210 210 210 210
Caliper (Ø pistons mm) 4-piston (Ø 25.4) 4-piston (Ø 25.4) 4-piston (Ø 25.4) 4-piston (Ø 25.4)
FRONT RIM
Material Aluminium alloy Forged aluminium alloy Aluminium alloy Forged aluminium alloy
Dimensions 3,50” x 17” 3,50” x 17” 3,50” x 17” 3,50” x 17”
REAR RIM
Material Aluminium alloy Forged aluminium alloy Aluminium alloy Forged aluminium alloy
Dimensions 6,00” x 17” 6,00” x 17” 6,00” x 17” 6,00” x 17”
TYRES
Front 120/70-ZR 17 (58 W) 120/70-ZR 17 (58 W) 120/70-ZR 17 (58 W) 120/70-ZR 17 (58 W)
Rear 190/55-ZR 17 (75 W) 190/55-ZR 17 (75 W) 190/55-ZR 17 (75 W) 190/55-ZR 17 (75 W)
Brand and type PIREllI - Diablo Supercorsa SP PIREllI - Diablo Supercorsa SP
PIREllI - Diablo Supercorsa SP PIREllI - Diablo Supercorsa SP
DUNlOP - Sportmax Qualifier RR DUNlOP - Sportmax Qualifier RR
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Maintenance
B
Front 2.3 bar (33 psi) 2.5 bar (36 psi) 2.3 bar (33 psi) 2.5 bar (36 psi) 2.3 bar (33 psi) 2.5 bar (36 psi) 2.3 bar (33 psi) 2.5 bar (36 psi)
Rear 2.3 bar (33 psi) 2.9 bar (42 psi) 2.3 bar (33 psi) 2.9 bar (42 psi) 2.3 bar (33 psi) 2.9 bar (42 psi) 2.3 bar (33 psi) 2.9 bar (42 psi)
ELECTRICAL SYSTEM
Equipment voltage 12V 12V 12V 12V
Headlight bulb PHIlIPS xenStart D1S 35W PHIlIPS xenStart D1S 35W PHIlIPS xenStart D1S 35W PHIlIPS xenStart D1S 35W
Tail light bulb 12V 5W 12V 5W 4 diodes - 12V 0.6W 4 diodes - 12V 0.6W
Battery 12V - 8.6Ah 12V - 8.6Ah 12V - 8.6Ah 12V - 8.6Ah
Alternator 350 W at 5000 rpm 350 W at 5000 rpm 350 W at 5000 rpm 350 W at 5000 rpm
BODYWORK
Fairing Thermoplastic material Thermoplastic material Thermoplastic material Thermoplastic material
Front fairing Thermoplastic material Thermoplastic material Thermoplastic material Thermoplastic material
Rear side panels Thermoplastic material Thermoplastic material Thermoplastic material Thermoplastic material
Fuel tank Thermoplastic material Thermoplastic material Thermoplastic material Thermoplastic material
Air box Thermoplastic material Thermoplastic material Thermoplastic material Thermoplastic material
Air scoops Thermoplastic material Thermoplastic material Thermoplastic material Thermoplastic material
Air box side panels Thermoplastic material Thermoplastic material Thermoplastic material Thermoplastic material
Front mudguard Thermoplastic material Thermoplastic material Thermoplastic material Thermoplastic material
Chain guards Thermoplastic material Thermoplastic material Thermoplastic material Thermoplastic material
Exhaust pipe guard Aluminium Aluminium Aluminium Aluminium
Heat shield Thermoplastic material Thermoplastic material Thermoplastic material Thermoplastic material
license-plate holder Thermoplastic material Thermoplastic material Thermoplastic material Thermoplastic material
* : If tyre brands other than those recommended are used, refer to the tyre pressure indicated by the manufacturer on the tyre side wall.
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Maintenance
B
1st 2.643 (12.341) 2.643 (12.341) 2.643 (12.341)
2nd 2.062 (9.631) 2.062 (9.631) 2.062 (9.631)
3rd 1.722 (8.042) 1.722 (8.042) 1.722 (8.042)
4th 1.500 (7.004) 1.500 (7.004) 1.500 (7.004)
5th 1.318 (6.155) 1.318 (6.155) 1.318 (6.155)
6th 1.190 (5.559) 1.190 (5.559) 1.190 (5.559)
FRAME
Type CrMo steel tubular CrMo steel tubular CrMo steel tubular
trellis (MAG welded) trellis (MAG welded) trellis (TIG welded)
Swingarm pivot plates Aluminium alloy Aluminium alloy Aluminium alloy
FRONT SUSPENSION
Type “Upside down” telescopic hydraulic fork “Upside down” telescopic hydraulic fork öHlINS Nix EC - “Upside down” telescopic
with external and separated adjustment with external and separated adjustment hydraulic fork with electronic adjustment
of rebound and compression damping of rebound and compression damping of rebound and compression damping
and of spring preload and of spring preload and of spring preload
Ø stems (mm) 50 50 43
Travel on leg axis (mm) 120 120 120
REAR SUSPENSION
Type Progressive, single shock absorber öHlINS TTx progressive, single öHlINS TTx progressive, single shock
with rebound-compression (High/low shock absorber with rebound- absorber with electronic adjustment of
speed) damping and spring preload compression damping and rebound-compression damping
adjustment spring preload adjustment and spring preload
Wheel travel (mm) 120 120 120
Swingarm Aluminium alloy Aluminium alloy Aluminium alloy
FRONT BRAKE
Type Dual floating disc with Dual floating disc with Dual floating disc with
steel braking band steel braking band steel braking band
Ø discs (mm) 320 320 320
Disc flanges Aluminium Aluminium Aluminium
Master cylinder Axial-type Axial-type Radial-type
Calipers (Ø pistons mm) Radial-type, single-piece Radial-type, single-piece Radial-type, single-piece
with 4 pistons (Ø 34) with 4 pistons (Ø 34) with 4 pistons (Ø 30)
REAR BRAKE
Type Single steel disc Single steel disc Single steel disc
Ø disc (mm) 210 210 210
Caliper (Ø pistons mm) 4-piston (Ø 25.4) 4-piston (Ø 25.4) 4-piston (Ø 25.4)
FRONT RIM
Material Aluminium alloy Forged aluminium alloy Forged aluminium alloy
Dimensions 3,50” x 17” 3,50” x 17” 3,50” x 17”
REAR RIM
Material Aluminium alloy Forged aluminium alloy Forged aluminium alloy
Dimensions 6,00” x 17” 6,00” x 17” 6,00” x 17”
TYRES
Front 120/70-ZR 17 (58 W) 120/70-ZR 17 (58 W) 120/70-ZR 17 (58 W)
Rear 200/55-ZR 17 (78 W) 200/55-ZR 17 (78 W) 200/55-ZR 17 (78 W)
Brand and type PIREllI - Diablo Supercorsa SP PIREllI - Diablo Supercorsa SP PIREllI - Diablo Supercorsa SP
Tyre pressure (*) Per velocità infe- Per velocità supe- Per velocità infe- Per velocità supe- Per velocità infe- Per velocità supe-
riori a 300 km/h riori a 300 km/h riori a 300 km/h riori a 300 km/h riori a 300 km/h riori a 300 km/h
Front 2.3 bar (33 psi) 2.5 bar (36 psi) 2.3 bar (33 psi) 2.5 bar (36 psi) 2.3 bar (33 psi) 2.5 bar (36 psi)
Rear 2.3 bar (33 psi) 2.9 bar (42 psi) 2.3 bar (33 psi) 2.9 bar (42 psi) 2.3 bar (33 psi) 2.9 bar (42 psi)
ELECTRICAL SYSTEM
Equipment voltage 12V 12V 12V
Headlight bulb PHIlIPS xenStart D1S 35W PHIlIPS xenStart D1S 35W PHIlIPS xenStart D1S 35W
Tail light bulb 4 diodes - 12V 0.6W 4 diodes - 12V 0.6W 4 diodes - 12V 0.6W
Battery 12V - 8,6Ah 12V - 8,6Ah 12V - 8,6Ah
Alternator 350 W at 5000 rpm 350 W at 5000 rpm 350 W at 5000 rpm
BODYWORK
Fairing Thermoplastic material Thermoplastic material Thermoplastic material
Front fairing Thermoplastic material Thermoplastic material Thermoplastic material
Rear side panels Thermoplastic material Thermoplastic material Thermoplastic material
Fuel tank Thermoplastic material Thermoplastic material Thermoplastic material
Air scoops Thermoplastic material Thermoplastic material Thermoplastic material
Air box Thermoplastic material Thermoplastic material Thermoplastic material
Air box side panels Thermoplastic material Thermoplastic material Thermoplastic material
Front mudguard Thermoplastic material Thermoplastic material Thermoplastic material
Chain guards Thermoplastic material Thermoplastic material Thermoplastic material
Exhaust pipe guard Aluminium Aluminium Aluminium
Heat shield Thermoplastic material Thermoplastic material Thermoplastic material
license-plate holder Thermoplastic material Thermoplastic material Thermoplastic material
* : If tyre brands other than those recommended are used, refer to the tyre pressure indicated by the manufacturer on the tyre side wall.
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Maintenance
B
For motorcycles used in particularly severe conditions, maintenance operations must be
WARNING
carried out more frequently.
We respect and defend the environment.
Everything that we do has repercussions on the whole planet and on its resources.
MV Agusta, to protect the interests of the everyone, ask clients and technical assistance operators to use
the motorcycle and dispose of its used parts with respect to the norms in force in terms of environmental
pollution, disposal and recycling of refuse.
u The information marked with this symbol only refers to F4 MY10 -> MY12 models.
The information marked with this symbol only refers to F4 S - FT - RR models.
Programmed maintenance schedule
0 1000 6000 12000 18000 24000 30000 36000
Km (mi) covered (600) (3800) (7500) (11200) (14900) (18600) (22400)
Pre-
Service delivery A B C D E F G
Description Operation
l l l l l l l
Engine oil Substitution
At least once a year
Substitution l l l l l l l
Engine oil filter (utilise only original MV
Agusta oil filters) At every substitution of engine oil
Check l l
Timing chain
Substitution l
Check / Substitution l l
Check / Substitution l l l
Spark plugs
Substitution l l l
Check level l l l l l l l
Check functioning l l l l l l l l
Brakes and clutch
Check circuit l l l l l l l l
Brake pads
Check / Substitution l l l l l l l
(front and rear)
Check for defects
and leakages l l l l l l l
Fuel tubes
Substitution At least every three years
Check functioning l l l l l l l l
w w w w w w w w
Throttle control
Check/adjust play
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Maintenance
B
Description Operation
Check / adjust l l l l l l l l
Substitution l l l
Check l l l l
Check l l l l
Rear sprocket l l l
Substitution
At least at each substitution of the transmission chain
Check / adjust l l l l
Steering bearings
lubricate l
Check pressure l l l l l l l l
Tyres
Check for wear l l l l l l l
l l l l l l l
Wheel rims Visual check
Every tyre substitution
l l l l l
Check
Front wheel bearings Every tyre substitution
Substitution l
Side
Check functioning l l l l l l l l
stand switch
lubricate roller
Check / bearings l l
Rear wheel hub lubricate roller
Substitution / bearings l
Check functioning l l l l l l l l
Front headlight
Adjust At every variation of the riding set-up of the motorcycle
General lubrication l l l l l l l l
General check l l l l l l l l
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Maintenance
B
50% distilled water
Brake and clutch fluid Agip Brake 4 DOT4
Chain lubrication oil D.I.D. CHAIN lUBE –
* : To find the recommended product, MV Agusta suggests going directly to the authorised MV Agusta dealers.
The eni i-Ride motoGP 10W/60 engine oil has been manufactured for the F4 engine. If the described oil is not
available, MV Agusta suggests using completely synthetic oils with characteristics equal or
better than the ones prescribed in the following standards:
– Conforming to API SG
– Conforming to ACEA A3 Engine oil
– Conforming to JASO MA SAE 10 W-60
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Maintenance
B
Remove the oil discharge plug (1).
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Maintenance
Replace the oil filter and put the cover back on.
35 N•m
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Maintenance
Oil pipes
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Maintenance
ENGINE COOLANT
Check / top-up level g At the pre-delivery, at
the first 1000 kilome-
tres and then every 1
6000 kilometres. B
Keeping the motorcycle in a vertical position, check
that the level of engine coolant is between the «MIN»
and «MAx» mark found on the expansion tank (1).
Max. level
Min. level
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Maintenance
Manutenzione
2
Substitutiong every two years
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Maintenance
Max. level
Min. level
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Maintenance
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Maintenance
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Maintenance
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Maintenance
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Maintenance
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Maintenance
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Maintenance
B
The correct measuring of the play is a fun-
damental operation for the correct function-
ing of the engine.
Valve play
Pad thickness
Valve play
Pad thickness
Valve play
Pad thickness
Valve play
Pad thickness
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Maintenance
1 2 3 4
1 2 3 4 5 6 7 8
INTAKE
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Maintenance
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Maintenance
Camshaft
Adjustment pad
Valve cup
Valve
The play values measured between the valve cup and cam must be the following:
For all intake valves 0.15 ÷ 0.24 mm
For all exhaust valves 0.20 ÷ 0.29 mm
If different values are encountered even for one valve, substitute the camshaft/valve cup play adjustment pads as
described in the F4 1000 workshop engine manual F4 1000 (Code 8000B4302).
If the values are correct, reassemble in reverse order to disassembly. Consult the F4 1000 workshop engine man-
ual (Code 8000B4302) for the specific torque pressures and the necessary products.
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Maintenance
SPARK PLUGS
Check/substitute g At 6000 kilometres and then
every 12000 kilometres
- F4 MY13:
Remove the plug-top coil fixing screws.
Pull out the four plug-top coils.
Remove the spark plugs utilising the appropriate 16
mm hexagonal spark plug spanner.
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Maintenance
Heat Grade
Check the heat grade of the spark plugs.
Sparks: - NGK CR9 EB
B
DO NOT use non-resistive spark plugs.
Electrode condition
Check the electrodes for wear or burning. If they are
extremely used or burnt, substitute the spark plugs.
Also substitute the spark plugs in the case of breakage
of the ceramic isolation or damage to threading.
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Maintenance
FUEL FILTERS
Check and substitute g Every 12.000 km
Insert the ignition key in the fuel filler cap lock and
rotate in a clockwise direction to open the fuel filler cap.
5 N•m
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Maintenance
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Maintenance
2 1
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Maintenance
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Maintenance
Remove the upper clamp in the same way and take out
the tube.
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Maintenance
Insert the upper tube in the new cartridge and fix with
a clamp taken from the new kit, using the special tool.
Insert the lower tube in the new cartridge and fix with a
clamp taken from the new kit, using the special tool.
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Maintenance
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Maintenance
1 8000B1958 1 • • • • •
B
1 8A00B1958 1 USA • • • • •
2 8000B4276 1 • • • • •
3 8000B4277 1 • • • • •
4 8000B4278 1 • • • • •
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Maintenance
• Fuel tank
• Rear side panels
• Seats
• Fuel tank side panels 3
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Maintenance
FUEL TUBE / FITTINGS
Check for leaks g First 1000 kilometres and then
every 6000 kilometres
Insert the new fuel tube onto the union of the throttle
body, until it has locked into place.
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Maintenance
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Maintenance
Twist off the plugs that close the vacuum tubes. The
number of the cylinder to which the rubber plug is con-
nected is written on the plug itself (A).
The vacuum tubes are located on the right and left side
of the vehicle.
B
Left side: Cylinders 1 and 2
Right side: Cylinders 3 and 4
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Maintenance
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Maintenance
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Maintenance
Twist off the plugs that close the vacuum tubes. The
number of the cylinder to which the rubber plug is con-
nected is written on the plug itself (A).
The vacuum tubes are located on the right and left side
B of the vehicle.
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Maintenance
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Maintenance
AIR FILTER
Check/substitute g Every 6000 kilometres
• Seats
• Right side panel tank
• left side panel tank
• Rear right side panel
• Rear left side panel
• Right side airbox panel
• left side airbox panel
• Fuel tank
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Maintenance
B
Unhook the two front clips (1) and remove the cover
(2).
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Maintenance
B
Unscrew the no. 7 fixing screws (1) and remove the air
filter (2).
5 ÷ 7 N•m
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Maintenance
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Maintenance
Fasten the cover with four screws (two per side) (1).
• Fuel tank
• left side airbox panel
• Right side airbox panel
• Rear left side panel
• Rear right side panel
• left side panel tank
• Right side panel tank
• Seats
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Maintenance
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Maintenance
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Maintenance
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Maintenance
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Maintenance
6 N•m
Footest adjustment
(F4 Frecce Tricolori / F4 RR)
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Maintenance
BRAKE PADS
Wear check / substitute g At the first 1000 kilo-
metres and then every
6000 kilometres
Disc
Wear limit: 1 mm
Pads
Wear limit 1 mm
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Maintenance
THROTTLE CONTROL
(F4 MY10 -> MY12)
Throttle control play checkg At the pre-delivery check,
B
at the first 1000 kilome-
tres and then every 6000 1
kilometres.
The throttle 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 throttle control
handgrip).
The lack of play on the closure of the throt-
tle control (1) can stop the complete closing
of the throttle valve and the throttle control
could remain in the open position, thereby
leaving the engine with a fast tickover.
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Maintenance
LOCKS
Check g At the pre-delivery, at the first 1000
kilometres and then every 6000 kilo-
metres.
B Ignition/steering block switch
“OFF” position
All electrical circuits are disactivated. The key can be
pulled out.
“ON” position
All electrical circuits are activated, the instruments and
warning lights carry out self-diagnosis and the engine
can be switched on. The key cannot be pulled out.
“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. Left side Right side
“P” position
Rotate the key from the “LOCK” position to the “P”
position. All electrical circuits are disactivated except
for the sidelights. The steering is blocked. The key can
be pulled out.
“P” position
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Maintenance
If the fuel filler cap does not function (the cap does not
close, the lock blocks, etc.) substitute it with a new one
as described in chapter C “Bodywork”.
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Maintenance
STEERING
Check and adjust g At the first 1000 kilometres
and then every 12000 kilo-
metres.
B
Check the steering components regularly according to
the above-mentioned intervals.
If it is necessary to carry out adjustments, operate as
described in chapter F “Suspension and wheels”.
TRANSMISSION CHAIN
Check g At the pre-delivery, at the first 1000
kilometres and then every 6000 kilo-
metres.
Substituteg Every 12000 km
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Maintenance
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Maintenance
Chain lubrication
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Maintenance
TYRES
Check pressuresg At the pre-delivery, at the first
1000 kilometres and then every
6000 kilometres.
B
Check wear g At the first 1000 kilometres and
then every 6000 kilometres.
If the tyre pressures are too high or too low, the ride is
affected and tyre life duration is accentuated.
Therefore maintain the correct tyre pressures to obtain
better roadholding and the maximum wear from the
tyres. The cold tyre pressures are indicated in the
table.
Tyre pressures
Brand and type PIRELLI - Diablo Supercorsa SP
DUNLOP - Sportmax Qualifier RR (F4 S / F4 FT)
At a speed lower than 300 km/h At a speed higher than 300 km/h
Front 2,3 bar (33 psi) 2,5 bar (36 psi)
Rear 2,3 bar (33 psi) 2,9 bar (42 psi)
1.5 mm
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Maintenance
WHEELS
Visual check g At the first 1000 kilometres and
then every 6000 kilometres (at
least every tyre change)
B
After having visually checked or following even light
collision damage, it is necessary to check the planari-
ty, the eccentricity and the ovalisation of the wheel.
See the control procedures described in chapter F
“Suspension and wheels”.
SWINGARM BEARINGS
Check and lubricate g Every 36000 kilometres
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Maintenance
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Maintenance
SIDE STAND
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Maintenance
FRONT FORK
Substitute oil g every 24000 kilometres
Recommended oil:
Marzocchi EBH16 SAE 7,5
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Maintenance
metres.
B
The instrumentation check must be carried out com-
pletely on all its functions as listed in the following list.
If even one of the functions does not function correct- Tachometer display
ly, consult chapter E “Electrical system” for complete
details.
Warning lights
1 Neutral warning light (green)
It turns on when the gear is in “Neutral”. 6
2 Turn indicator light (green) 5 7 8
Lights up when the turn indicators are activated. 4
3 Headlights (blue) 3
It turns on when the headlights are on. 2
1
4 - F4 MY10 -> MY12:
Battery charge indicator (red)
Lights up when the alternator does not supply enou-
gh current to charge the battery. If the indicator
comes on while riding, contact an authorized service
centre.
- F4 MY13:
ABS warning light (orange) *
Lights up when the ABS system has a fault or is
deactivated. If it lights up while riding, contact an
authorized service centre.
5 Engine oil pressure warning lights (red) F4 MY10 -> MY12
Lights up when the oil pressure is insufficient.
If the warning light comes on while riding,
stop the motorcycle immediately. Check the 6
5 7 8
oil level and if necessary have it restored. If 4
the warning light comes on even if the oil
3
level is correct, do not resume riding and con- 2
tact a MV Agusta authorized service centre. 1
6 Sidestand down warning light (red)
Lights up when the sidestand is down.
7 Reserve fuel indicator (orange)
Comes on when approximately 4 litres of fuel are
left.
8 Rev limiter warning light (red)
It turns on when the engine exceeds 10800 rpm;
the rev limiter limits the rpm to 13500.
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Maintenance
Multifunction display
13
10 Thermometer 12
11
It displays the temperature of the coolant by turning 10 14
on a variable number of segments on a graduated
scale. When the temperature falls outside the nor- B
mal operating range, it may display one of the fol-
lowing information:
- the display shows just one blinking segment; it
means that the temperature is low;
- all segments are on, while the upper segment is
blinking; it means that the temperature is high.
11 Gear display
It displays the currently engaged gear.
“N” stands for “neutral”.
12 Speedometer
It displays the speed of the motorbike. It can be
given in kilometres per hour (Km/h) or in miles per
hour (Mph). The full scale measures 350 Km/h
(217 Mph).
13 “SPORT” Mode
It puts the injection unit in Sport Mode.
14 “SET” button
Press it to select and set the figures on the display.
15 “OK” button
Press it to confirm the new settings.
16 “TOTAL” odometer:
It displays the total distance covered; from 0 to
999999 (Km or miles)
Trip counter 1, “TRIP 1”
It displays the length of a trip; from 0 to 999.9 (Km
or miles)
Trip counter 2, “TRIP 2”
It displays the length of a trip; from 0 to 999.9 (Km
or miles)
Chronometer
It displays the time measured by the chronometer
17 “HAZARD” button
Press it to turn on the emergency lights.
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Maintenance
“RUN” (Odometer)
“TC” (Traction control)
“CHRONO” (Chronometer)
“NIGHT/DAY” (Night/Day Mode)
“SETTING ÖHLINS” (Electronic suspension
adjustment) (F4 RR MY13)
“ABS” (Antilock braking system)* (MY13)
“QUICK SHIFT” (MY13)
• “RUN” (Odometer)
• “TC” (Traction control)
• “CHRONO” (Chronometer)
• “NIGHT/DAY” (Night/Day Mode)
• “SETTING ÖHLINS” (Electronic suspension
adjustment) (F4 RR MY13)
• “ABS” (Antilock braking system)* (MY13)
• “QUICK SHIFT” (MY13)
WARNING
The operation must be performed while the
engine off, the gears are in neutral, the
motorcycle is stationary, and with the feet
on the ground. Do not set the display func-
tions while riding.
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Maintenance
“RUN” mode
In addition to the speedometer, the display shows the
following functions:
• Total odometer
• Trip counter 1
“TOTAL”
“TRIP 1”
B
alternatively:
“TC” Mode
This Mode adjusts the engine traction control level to
your driving requirements.
“CHRONO” Mode
This mode turns on the Chronometer and saves the
recorded information. The following is displayed:
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Maintenance
“NIGHT/DAY” Mode
This function enables the background colour of the dis-
play to be converted in order to adapt its visibility
depending on the time of day or night the vehicle is
B used.
• Front suspension
• Rear suspension
• Steering damper
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Maintenance
Trip reset
To reset “TRIP 1” and “TRIP 2”, proceed as follows.
WARNING
The display modes may be changed or set
when the engine off, the gear in neutral, the
motorbike stationary with your feet on the
ground. The display may not be changed
while driving.
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Maintenance
- Press the “OK” key for less than three seconds until
the partial speedometer 2 function (“TRIP 2”) appears
on the display.
“TC” Mode
- Press the "SET" button to switch on "TC" mode, then
press the "OK" button for less than three seconds
until the message "TC LEVEL" appears. The current
traction control level is the value displayed.
WARNING
The display modes may be changed or set
when the engine off, the gear in neutral, the
motorbike stationary with your feet on the
ground. Do not change the display while dri-
ving.
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Maintenance
Chronometer
Lap timing acquisition
- Turn on the chronometer (“CHRONO” mode) to
record the time taken to cover a lap.
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Maintenance
When the time for the lap which has just concluded is
displayed, the symbol “+” or “-” appears if the time
recorded is respectively higher or lower than the time
measured during the previous lap.
Data display
Once all times have been recorded, they may be
displayed.
WARNING
The display modes may be changed or set
when the engine off, the gear must be in
neutral, the motorbike must be stationary
with your feet on the ground. Do not change
the display while driving.
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Maintenance
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Maintenance
B WARNING
The display modes may be changed or set
when the engine off, the gear in neutral, the
motorbike stationary with your feet on the
ground. Do not change the display while dri-
ving.
- Press the “OK” key for less than three seconds; the
value of the last lap time memorised will start flashing.
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Maintenance
- Press the “OK” key for less than three seconds; the
value of the fastest last lap time memorised will start
flashing.
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Maintenance
- Press the “OK” key for less than three seconds; the
display will ask you to confirm cancellation of all the
data present in the memory.
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Maintenance
“NIGHT/DAY” Mode
WARNING
The display modes may be changed or set
when the engine off, the gear in neutral, the
motorbike stationary with your feet on the
ground. Do not change the display while dri-
ving.
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Maintenance
“IMMOBILIZER” function
- Press the "OK " button for less than three seconds to
set the first number of the code.
- Press the "OK " button for less than three seconds to
vary the first number value between 0 and 9.
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Maintenance
- Once the digit has been selected, press “OK” for over
three seconds to confirm the first digit of the code.
Now, you can set the second digit of the code.
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Maintenance
WARNING
The display modes may be changed or set
when the engine is off, the gear in neutral,
the motorbike stationary with your feet on
the ground. Do not change the display while
driving.
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Maintenance
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Maintenance
q Steering damper
WARNING
The display modes may be changed or set
when the engine is off, the gear in neutral,
the motorbike stationary with your feet on
the ground. Do not change the display while
driving.
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Maintenance
WARNING
The “ABS RACE” function has been expres-
sly studied for use of the vehicle on race
track. MV Agusta recommends not to use this
function when riding on public roads.
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Maintenance
WARNING
The display modes may be changed or set
when the engine is off, the gear in neutral,
the motorbike stationary with your feet on
the ground. Do not change the display while
driving.
- Press the "OK" button for less than three seconds; the
activation caption of the “quick shift” function begins
to flash.
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Maintenance
Mapping N R S C
WARNING
The “Custom” mapping setting operations
must be performed when the the gear is in
neutral and the motorbike stationary with
your feet on the ground. Do not change the
display while driving.
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Maintenance
• “NORMAL”
• “RAIN”
• “SPORT”
- Press “OK” for more than three seconds; the new set-
ting will be confirmed. The displayed caption stops
flashing and after a few seconds the display returns to
“GAS SENSITIVITY” mode. It is now possible to pro-
ceed with the setting of the following parameter.
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Maintenance
- Press “OK” for more than three seconds; the new set-
ting will be confirmed. The displayed caption stops
flashing and after a few seconds the display returns to
“MAX ENGINE TORQUE” mode.
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Maintenance
• “NORMAL”
• “SPORT”
- Press “OK” for more than three seconds; the new set-
ting will be confirmed. The displayed caption stops
flashing and after a few seconds the display returns to
“ENGINE BRAKE” mode.
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Maintenance
- Press “OK” for more than three seconds; the new set-
ting will be confirmed. The displayed caption stops
flashing and after a few seconds the display returns to
“ENGINE RESPONSE” mode.
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Maintenance
• “NORMAL”
• “SPORT”
- Press “OK” for more than three seconds; the new set-
ting will be confirmed. The displayed caption stops
flashing and after a few seconds the display returns to
“RPM LIMITER” mode.
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Maintenance
WARNING
Whenever the diagnostic tests detect a fault
with the vehicle stopped, do not start up the
machine and contact an authorised MV
Agusta service centre.
WARNING
Whenever a fault is detected while the vehi-
cle is running, stop running and contact an
authorised MV Agusta service centre.
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Maintenance
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Maintenance
DEAlER MENU
“SERVICE” Mode
WARNING
The modification or adjustment of display
functions must be carried out with the engi-
ne off and running on neutral, with the
motorcycle stopped with the stands on the
ground. Changing display settings while
running is prohibited.
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Maintenance
- Press the "OK " button for less than three seconds
until the message "SERVICE" is displayed. The
mileage range with respect to expiration of the next
scheduled maintenance is shown on this screen.
B
- Press the "OK " button for more than three seconds
and the mileage range will be reset. The mileage
range with respect to expiration of the next scheduled
maintenance is shown on this screen.
- The next press of the "SET" button for less than three
seconds will allow the user to return to the dashboard
start screen.
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Maintenance
• Speed
B
• Distance covered
WARNING
The modification or adjustment of display
functions must be carried out with the engi-
ne off and running on neutral, with the
motorcycle stopped with the stands on the
ground. Changing display settings while
running is prohibited.
- Press the "OK " button for less than three seconds
and the unit on the speedometer will begin to flash.
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Maintenance
- Press the "OK " button for more than three seconds
and the new unit of measurement configuration will
be confirmed. The display returns to the "RUN" mode.
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Maintenance
lIGHTS
Check g At the pre-delivery, at the first 1000
kilometres and then every 6000 kilo-
metres.
B
If any of the warning lights or the main lights are burnt
out, replace them as follows.
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Maintenance
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Maintenance
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Maintenance
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Maintenance
- Pull out the bulb holder and remove the license plate
light support from the license plate holder.
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Maintenance
FUSES
Solenoid
starter
CAUTIoN
Turn the ignition key on the “oFF” position
before checking or replacing the fuses, in
order to avoid a short circuit with subse- Recharge fuse (40 A)
motorcycle.
WARNING
Never replace a fuse with a rating other than
that precribed, in order to avoid damage to
the electrical equipment of the motorcycle
which could lead to a fire.
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Maintenance
- Release the two clamps and lift the fuse box cover.
B
CAUTIoN
Turn the ignition key on the “oFF” position
before checking or replacing the fuses, in
order to avoid a short circuit with subse-
quent damage to other electric parts of the
motorcycle.
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Maintenance
WARNING
Never replace a fuse with a rating other than
that precribed, in order to avoid damage to
the electrical equipment of the motorcycle
which could lead to a fire.
7.5A
7.5A
15A
15A
15A
15A
15A
ABS Fuses - Replacement (MY13) *
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Maintenance
FRoNT HEADlAMP
Check adjustment g At every variation of the motorcycle set-up.
The headlight should be adjusted every time the geometry of the vehicle is altered and before carrying a pillion
passenger. The motorcycle is not equipped with external adjusters and the front projector unit is fixed to the B
frame.
Headlight adjustment
Place the vehicle at a distance of 10 m from a vertical wall. Make sure that the motorcycle is placed on an even
horizontal surface, and that the headlight’s optical axis is perpendicular to the wall.
The vehicle must be held in an upright position. Measure the “X” distance between the headlight center and the
ground surface, then trace a small cross on the wall at the same height.
When you turn the headlight on, the upper boundary line between the dark area and the lighted area must be at
an height equal or lower than the 9/10 of the headlight center height.
Headlight center
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Maintenance
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Bodywork
SECTION
Revision 1
C
-1-
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Bodywork
SUMMARY
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Bodywork
FAIRING ASSEMBLY
Right side
Left side
• This exploded view demonstrates the position of the bodywork and the method of disassembly and assembly.
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Bodywork
C
1
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Bodywork
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Bodywork
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Bodywork
-7-
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Bodywork
TAIL UNIT
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Bodywork
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Bodywork
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Bodywork
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Bodywork
FUEL TANK
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Bodywork
C
B
- 13 -
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Bodywork
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Bodywork
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Bodywork
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Bodywork
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Bodywork
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Bodywork
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Bodywork
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Bodywork
Airbox removal
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Bodywork
1
2
- 22 -
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Bodywork
Lift the air box from its rear part, removing the rubber
tube.
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Bodywork
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Bodywork
HEAT SHIELD
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Bodywork
Remove the four fixing screws, two upper (1) and two
lower (2), of the rear headlight support and remove the
support. 1
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Bodywork
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Bodywork
Right side
Left side
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Bodywork
C
1
Remove the two fixing screws (2) and remove the cen-
tral manifold (3).
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Bodywork
Unscrew and remove the two screws (1), one per part. 1
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Air intake injection system
SECTION
Revision 2
D
-1-
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Air intake injection system
SUMMARY
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Air intake injection system
BASIC
Accelerator opening signal
Accelerator position sensor INJECTION
TIME
FINAL
Injection signal INJECTION
Injectors TIME
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Air intake injection system
The various sensors allow the injection time (volume) compensations to be carried out on the basis of the fol-
lowing signals.
SIGNAL DESCRIPTION
AIR INTAKE TEMPERATURE SENSOR SIGNAL When the temperature of the intake air is low, the
injection time (volume) is increased.
BATTERY VOLTAGE SIGNAL The voltage of the battery is supplied to the ECU for
the functioning of the ECU and this voltage is
revealed and utilised as a signal for the compensa-
tion of the injection time (volume). A low voltage
determines a longer injection time for the adjustment
of the volume of the injection.
SIGNAL DESCRIPTION
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Air intake injection system
The fuel feed system is composed of tank, pump, filter, feed tube, feed tubes (including the fuel injectors) and
pressure regulator. The fuel in the tank is pumped into the feed tubing at a controlled pressure by the relative reg-
ulator and maintained at a certain constant value higher than the suction generated by the motor. The fuel is
injected into the air intake conduit when the injector opens, following a law generated by the ECU.
DISCHARGE OF
FUEL VAPORS
FUEL FILTER
FUEL PUMP
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Air intake injection system
The fuel pressure regulator is a diaphragm pressure release valve that consists of a diaphragm, spring and valve.
It always maintains the pressure of the fuel sent to the injector equal to the following value:
- F4 MY10 -> MY12: 3,0 kg/cm2 (300 kPa)
- F4 MY13: 3,5 kg/cm2 (350 kPa)
When the pressure of the fuel rises above this value, the excess fuel opens the valve of the regulator and there-
fore can return to the fuel tank.
FUEL INJECTOR
The fuel injector consists of a solenoid, piston, needle valve and a filter.
The injector is a small electromagnetic injection nozzle that injects fuel into the carburettor according to the sig-
nal coming from the ECU.
When the solenoid is agitated by the ECU, it becomes an electromagnet and attracts the piston. At the same time,
the needle valve incorporated in the piston opens and the injector, under pressure of the fuel, injects the fuel in
a conical dispersion. Given that the opening of the needle valve is constant, the volume of fuel injected at any
one time is dependent on the time that the solenoid is agitated (injection time).
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Air intake injection system
As the CPU possesses a timer function, the pump motor stops turning three seconds after the ignition switch has
been brought to the "ON" position. If the starter motor turns the electric motor shaft during or after the three sec-
onds, the motor rotation signal is sent to the CPU that, by controlling the pump relay, makes the pump motor func-
tion continuously.
When the ignition switch is switched to the "OFF" position, the control of the pump relay is interrupted and con-
temporaneously also the control of the injectors and the ignition coils, thereby causing the engine to switch off.
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Air intake injection system
ECU
The ECU consists of a CPU (Central Processing Unit),
a memory unit and I/O sections (input/output).
The signal of each individual sensor is sent to the input
section and then to the CPU. On the basis of the sig-
nals received, the ECU calculates the volume of fuel
and the ignition advance necessary by utilising pre-
pared schemes for the various conditions of the engine
and sending them respectively to the injectors and the
ignition coils.
SENSORS
ATMOSPHERIC AIR TEMPERATURE/PRESSURE
The suction air sensor (1) is situated on the right suc-
tion duct in the front part of the vehicle and indicates
both the atmospheric pressure and the air temperatu-
re.
Output voltage
(V)
High
Pressure of the
2
Low
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Air intake injection system
D
Resistance value
High
Low
A B
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Air intake injection system
A – – (pin 16)
B – + 5V (pin 14)
C – Signal (pin 30)
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Air intake injection system
INJECTOR CHECK
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Air intake injection system
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Air intake injection system
ACTUATORS
Fuel injector
The fuel injector consists of a solenoid, piston, needle valve and a filter.
The injector is a small electromagnetic injection nozzle that injects fuel into the carburettor according to the signal
coming from the ECU.
When the solenoid is agitated by the ECU, it becomes an electromagnet and attracts the piston. At the same time,
the needle valve incorporated in the piston opens and the injector, under pressure of the fuel, injects the fuel in
a conical dispersion. Given that the opening of the needle valve is constant, the volume of fuel injected at any
one time is dependent on the time that the solenoid is agitated (injection time).
Ignition coils
The ignition coils are of the top plug type (they are assembled directly on the spark plugs. This avoids the use of
the HT leads and enhance the overall system reliability.
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Air intake injection system
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Air intake injection system
This motorcycle utilises direct induction in the air intake system. The frontal pressure of the air during normal rid-
ing conditions is conducted to the air filter compartment in such a way that the incoming air is pressurised there-
by improving the air intake efficiency to obtain greater power from the engine.
AIR FILTER
INCOME AIR-BOX
TSS SYSTEM
INTAKE MANIFOLD
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Air intake injection system
F4 bikes use an additional system for the secondary flow of induction air. Through this system, part of the air from
the Airbox is channelled near the exhaust pipes of the cylinder through a set of on/off valves and passageways
inside the engine head. So, when needed, the system promotes the post-combustion of any un-burnt hydrocar-
bons in the exhaust gases, thereby reducing the emission of pollutants into the atmosphere..
SECONDARY AIR VALVE
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Air intake injection system
SERVICE FUSE
MAIN RELAY
INJECTOR FUSE
FULE PUMP,
INJECTORS RELAY
FUEL PUMP - COILS -
Side stand out SWITCH SWITCH BATTERY
Gear engaged
Clutch released
Engine switched on
- 19 -
TILT SENSOR
Air intake injection system
PLUG-TOP
COILS
PRESSURE SENSOR
THROTTLE BODY
UNDER THROTTLE
UPPER INJECTRS
SIDE STAND SWITCH
PICK-UP WHEEL
THROTTLE BODY
LOWER INJECTRS
D
Air intake injection system
D
PWS_GND Mass power POWER-GROUND 16
SNSSPLY_GND Analogic mass 1 SENSOR-GROUND 17
RPM- Input r.p.m. sensor (-) (VRS -) IFA,DIFFERENZIALE 20
O2SENS-1 Input Lambda sensor (-) N°1 IA,DIFFERENZIALE 22
MANPRES1 Input sensor of air pressure collector/barometric IA,PULL-DWN,RATIO 24
SNSSPLY1 Output VREF1 +5V, for TPS SENSOR-SUPPLY 25
IGN2 Output coil control N°2 OFA,LOW-SIDE 27
IGN1 Output coil control N°1 OFA,LOW-SIDE 28
DBW1- Output command- DCM exhaust butterfly valve OP,H-BRIDGE 29
HWRES_SPAR1 Suction valve control output OD,LOW-SIDE 31
O2HEAT1 Output PWM command Lambda heater N°1 OP,LOW-SIDE 32
INJ3_1 Injector control output N°3 block 2 high injectors OFA,LOW-SIDE 34
RPM+ Input r.p.m. sensor (+) (VRS +) IFA,DIFFERENZIALE 35
AIRTEMPA Input air temperature sensor signal IA,PULL-UP,RATIO 37
KEYREQ Input switch control panel key ID,PULL-DWN 40
DBW1+ Output command + DCM exhaust butterfly valve OP-HBRIDGE 41
PPWS_BAT Control unit direct protected power POWER-SUPPLY 42
O2HEAT2 Output PWM command EBS valve OP,LOW-SIDE 44
INJ4_1 Injector control output N°4 block 2 high injectors OFA,LOW-SIDE 45
INJ2_1 Injector control output N°2 block 2 high injectors OFA,LOW-SIDE 46
PHASEIN Input engine HALL phase sensor IFA,PULL-UP 47
TPS1 Throttle body throttle position input (TPS) IA,PULL-UP,RATIO 48
TPSRED1 Exhaust valve throttle position input IA,PULL-UP,RATIO 50
SNSSPLY1 Output VREF 1 +5V, for TPS SENSOR-SUPPLY 51
PWS Direct power supply to control unit POWER-SUPPLY 52
INJ1_2 Injector control output N°1 block 1 low injectors OFA,LOW-SIDE 53
WARNLAMP Output command “Warning Lamp” OD,LOW-SIDE 54
CANISTVALVE Output command “secondary Air” valve OP,LOW-SIDE 55
CLUTCHSW Input clutch sensor switch ID,PULL-UP 56
SNSSPLY2_GND Pressure sensor analog mass SENSOR-GROUND 57
ENGSTART Input switch “start engine” ID,PULL-UP 58
HARDWIRING Output light relay command OD,LOW-SIDE 60
FANRELA_FANVALVE Output relay command electric fan OD,LOW-SIDE 61
VENTVALV_TRBT Output TSS valve control OD,LOW-SIDE 62
SNSSPLY2 VREF2 +5V ,output, for atmospheric pressure sensor SENSOR-SUPPLY 63
NEUTRALSW Input switch sensor idle ID,PULL-UP 64
TIPOVER Input tilt switch sensor ID,PULL-UP 65
CANL CAN Line L ( HIGH SPEED ) BC,HIGHT SPEED 66
INJ2_2 Injector control output N°2 block 1 low injectors OFA,LOW-SIDE 67
INJ4_2 Injector control output N°4 block 1 low injectors OFA,LOW-SIDE 68
AB_AVVIA Output direct command remote control solenoid starter OD,LOW-SIDE 69
SIDESTAND Input switch side-stand ID,PULL-UP 70
IVGTPS Input analogic sensor gear IA,PULL-UP,RATIO 72
FPUMPREL Output power relay control (fuel pump - coil - injectors) OD,LOW-SIDE 73
INJ3_2 Injector control output N°3 block 1 low injectors OFA,LOW-SIDE 74
TACHOUT R.p.m. counter control output OP,LOW-SIDE 75
SPAREDG Calibration map selection digital input ID,PULL-UP 76
RUNSTOPSW Input switch “engine stop” IA,PULL-DWN 78
VEHSPD Input HALL sensor vehicle speed IFT,PULL-UP 79
CANH CAN Line H ( HIGH SPEED ) BC,HIGHT SPEED 80
AI: Analog input - DI Digital input - AIF: Analog input frequency - DIF: Digital input frequency - FO: Frequency output -
DO: Digital output- PO: PWM digital output- BC: Communication line
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Electrical system
SECTION
Revision 3
E
-1-
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Electrical system
SUMMARY
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 3
COUPLINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 3
FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 3
SEMICONDUCTOR PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 4
ELECTRICAL DIAGRAM (F4 S - F4 Frecce Tricolori) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 5
PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 6
ELECTRICAL DIAGRAM (F4 R - RR MY12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 7
PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 8
ELECTRICAL DIAGRAM (F4 - F4 R - F4 RR MY13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 9
PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 10
ELECTRICAL DIAGRAM (F4 - F4 R - F4 RR MY13) (ABS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 11
PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 12
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 13
INITIAL CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 13
BATTERY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 14
BATTERY RECHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 17
E RECHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 18
VOLTAGE REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 18
EFFICIENCY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 20
STARTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 21
STARTER MOTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 28
STARTER MOTOR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 28
STARTER MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 29
STARTER RELAY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 29
TILT SENSOR (MY10->MY12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 31
LEAN SENSOR (MY13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 31
GEAR POSITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 32
SIDE STAND SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 32
FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 33
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 34
MAIN RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 35
ENGINE PICK-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 36
EAS (MY13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 36
TIMING WHEEL GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 37
RUN-OFF SAFETY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 37
INSTRUMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 38
OIL PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 39
FUEL LEVEL WARNING LIGHT SWITCH CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 39
WATER SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 40
IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 41
STARTER RELAY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 41
TURN INDICATORS CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 41
R.P.M. SENSOR (MY10->MY12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 41
INTERMITTENCE RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 42
DIAGNOSTICS UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 42
LAMBDA SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 42
ABS UNIT (MY13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 43
ELECTRONIC SUSPENSIONS UNIT (F4 RR MY13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 43
SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 43
LOW BEAM HEADLIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 44
HIGH BEAM HEADLIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 44
TURN INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 46
REAR TAIL LIGHTS AND BRAKE LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 46
LICENCE PLATE LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 46
ELECTRIC FAN COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 47
HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 47
SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 48
POSITIONING OF ELECTRICAL SYSTEM WIRE CLAMPS (F4 MY10 -> MY12) . . . . . . . . . . . . . . . .PAGE 49
POSITIONING OF ELECTRICAL SYSTEM WIRE CLAMPS (F4 MY13) . . . . . . . . . . . . . . . . . . . . . . . .PAGE 60
POSITIONING OF ELECTRICAL SYSTEM WIRE CLAMPS (F4 MY13 ABS) . . . . . . . . . . . . . . . . . . . .PAGE 77
-2-
Downloaded from www.Manualslib.com manuals search engine
Electrical system
CONNECTORS
• When a connector is connected, check that it clicks
into position.
• Check the connector for corrosion, dirt or a broken
cover.
CLICK
COUPLINGS
• Block couplings – ensure that the block is released CLICK
before disconnecting it to push it completely home
when connecting it.
• When disconnecting 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 the
original one.
• Do not utilise wire or any other substitute for the
fuse.
-3-
Downloaded from www.Manualslib.com manuals search engine
Electrical system
SEMICONDUCTOR PARTS
• Do not drop semiconductor parts such as those
INCORRECT
incorporated in the ECU.
• When checking these parts, carry out the instruc-
tions to the letter. The lack of using the correct pro-
cedure can cause grave damage.
-4-
Downloaded from www.Manualslib.com manuals search engine
E_Schema_Elettrico_GB_Rev.3_E_Schema_Elettrico_GB_Rev.3.qxd 23/05/13 14:58 Pagina 1
Electrical system
F1 F2 F3 F4 F5 F6 F7
35 34 57
R R/G Gy/R B/Y
LOCK
RUN
S TA R T
OFF
32 56 18 33 29 31 30 30
PA R K
OFF
ON
15A
15A
15A
15A
15A
15A
15A
F1 F2 F3 44 6 20 47 F4 F5 F6 F7
21 45 58 59 60 61
DOWN
UP
PUSH
FREE
8
G
Gr/R
G/O
R/G
B/Y
Bk
1 2 3 4
G
10 5 9 12 8 2 3 6 7 4 11 1 2 4 3 2 1 3 2 1
30
3 1 2 5 4 4 3 2 1
15A
15A
15A
15A
15A
15A
15A
R-O-F IGP L-O-R BATT R-O-R R-SW L-SW GND ID-W H-SW L-O-F
Br
R/G
Y/G
11
N
2
1 2 1 2
R/Bk 107
B/Y 130
3
Gy 105
4
G 106
B/Y 132
O/Bk 78
B/Y 142
2 3 1
5
4 3 2 1 2 1
Lb 84
E
W/Br 112
B 26
V/Bk 111
O/G 135
R/G 10
30
30
30
30
86
87
85
85
87
86
85
87
86
85
87
86
O/B 12
Y/R 11
B
G 103
B 158
A
A
A
O/Bk 141
R/Bk 115
R/Bk 116
B 28
B/Y 134
O/W 81
R/B 121
Lb 119
2 1 2 1 2 1 2 1
Lb 118
Bk 117
R 159
R8
B C A D E
Y/Bk 54
Y/Bk 53
B 19
B 20
B/Y 131
G 104
Gy/Y 109
O/Bk 127-128
Y/G 152
B/Y 130-131
Y/Bk 53-54
O/Bk 128
O/Bk 127
P/R 69
R/W 125
W/Bk 98
R/W 101
Bk/W 64
P/R 67-68
Bk/G 66
V 100
B 133
Y/Bk 52
Y/Bk 52
P/Y 143
Bk/R 65
O/G 40
O/G 41
O/G 42
O/G 40
G/O 86
O/G 43
R/G 10
P/R 67
B/R 48
Bk 129
B 27
O/G 44
O/G 45
P/R 74
P/R 75
P/R 76
P/R 77
B 18
P/R 68
P/R 69
O 122
O 102
Bk 93
Bk 94
Bk 63
B 21
R 2
R 6
R 4
R 5
36 1
2
R/Bk 115
B 29
R/Bk 116
B 25
1
2
3
3 B 39
4 B 30
4
ELLIPTICAL MODULE
Lb 119 1
B 23 2
1 W 154
BIFUNCTION CARD
7
G 103 2
W/Br 114 1
B 22 3
38
11 B/Y 136 B 17 16_M
9 R/B 121
8 Bk 117 Br 59 8_M
14 R 161 Br/W 60 46_M
15 Bk 160 Br/Bk 61 34_M
7 V 100 Br/G 62 45_M
1 R9 R7 52_M
10 P 85 R/Y 149 25_M
O/B 12 58_V
47_M
V/Bk 83 37_M
O/G 46 40_M
46 Y/R 11
R/Y 151
Gy 57
78_V
63_V
2_M 1
41
Gy/B 58 1_M
B/Y 137 B 16 5_M
44_M
Gr 79 R/Bk 107 32_M
76_V
Gy/B 108 14_M
W 95 35_M
Gy/Y 109 70_V
G/O 86 73_V
W/Bk 98 61_V
Br 96 20_M
R/W 125 31_M
Br/G 110 12_M
54_V
O/Y 13 69_V
Y/G 152 72_V
Bk/V 88 65_V
40 1
2
Lb 118
B 32
Bk/W 92 56_V
Br/Bk 61
Br/W 60
Gy 105
Br/G 62
10_M
P/R 71
Br 59
P/R 73
G 106 22_M
Bk 63
O/Bk 141
53_V
V/Bk 111
B/Y 138
W 154
Bk/W 92
O-W 81
B 14-15-16-17-18-35
Gr 79
B 99
Bk/W 64 67_V
B 34
B 33
O 122
2 1 3 5 4 6 Bk/G 66 68_V
B/Y 139
Br 96
G/W 80
W 95
Bk/R 65
97
74_V
42
Br/Bk 169
Br/W 167
Gy/Bk 55
Br/G 170
P/R 165
Br/G 110
P/R 168
Gy/G 56
Gy/B 58
Br 166
P/Y 146
B P/Y 147
B/R 51
B/R 50
B/R 49
B/R 48
R/Y 149
P/Y 145
Gy 57
P/Y 144
Bk/V 88
W/G 87
O/G 47
B 38
B 37
B 36
B 35
Gy/B 108
TEMP.
A V/Bk 83 Y/B 90 80_V
5 4 7 6 2 9 10 1 8 3 11 12 O/Bk 91 66_V
B 70
R3
1 2 3
F8
R/Y 151
B14
P/Y 148
R1
W/R 82
1 2
P 85
171
172
B/Y
Bk
Gy
Lb
O/Bk
Bk/B
W/B
R/G
P/R
O/Y 13
B
R1
1 2 1 2 1 2 1 2 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 2 1 1 2
O/Bk
O/Bk
40 A
B A C
48
1 2 3 2 3 1
B
LO
O/Bk 163
PASSING
B/Y 164
Y/B 162
1 2 3 4 B/Y 140 3 1 4 5 6
C
B
HORN
B 15
HI
R 2-3 40 A
51
TURN
PRESS.
5 6 7 8
53 F9 5
49 27 22 23 24 25 26 19 50 52 17 9 10 65
2 3 4 1
39
POS.
28
65
43 13 14 15 16 12 55 54
-5-
Electrical system
E
12 R.p.m. sensor 44 Relay ballast headlight
13 Coil 45 Exhaust valve actuator
14 Coil 46 Immobilizer Antenna
15 Coil 47 Fan relay
16 Coil 48 Battery recharge
17 Alternator 49 Clutch switch
18 Speed sensor 50 Starter motor
19 Solenoid starter 51 Engine earth
20 General feed relay 52 Voltage regulator
21 Intermittence 53 TSS valve
22-23 Upper injectors 54 Additional CAN socket
24-25 Upper injectors 55 Angular switch
26 Throttle potentiometer 56 Secondary air system
27 Water temperature sensor – CPU 57 Lambda sensor
28 Oil switch 58-59 Lower injectors
29 Electric fan 60-61 Lower injectors
30 Fuses
31 Electric fan
32 Side stand switch
33 Rear stop switch
-6-
Electrical system
35 34 57
R R/G Gy/R B/Y
F1 F2 F3 F4 F5 F6 F7
LOCK
S TA R T
RUN
OFF
32 56 18 33 29 31 30 30
PA R K
OFF
ON
F1 F2 F3 44 6 20 47 F4 F5 F6 F7
21 45 58 59 60 61
DOWN
UP
PUSH
FREE
8
G
Y/G
G/Y
R/Y
Bk
1 2 3 4
B
G
O
10 5 9 12 8 2 3 6 7 4 11 1 2 4 3 2 1 3 2 1
3 1 2 6 5 4 4 3 2 1
15A
15A
15A
15A
15A
15A
15A
15A
15A
15A
15A
15A
15A
15A
R-O-F IGP L-O-R BATT R-O-R R-SW L-SW GND ID-W H-SW L-O-F
Br
R/G
Y/G
11
N
2
1 2 1 2
R/Bk 107
B/Y 130
3
Gy 105
4
G 106
B/Y 132
O/Bk 78
B/Y 142
2 3 1 4 3 2 1
5
2 1
Lb 84
6
W/Br 112
B 26
E
R/G 176
B/Y 138
O/G 135
30
30
30
30
85
87
86
85
87
86
85
86
87
85
R/G 10
87
86
O/B 12
B
Y/R 11
B
A
A
G 103
B 158
O/Bk 141
R/Bk 115
R/Bk 116
B 28
B/Y 134
O/W 81
R/B 121
2 1 2 1 2 1 2 1
Lb 119
Lb 118
Bk 117
R8
R 159
B C A D E
Y/Bk 54
Y/Bk 53
30
B 19
B 20
B/Y 131
G 104
Gy/Y 109
O/Bk 127-128
Y/G 152
B/Y 130-131
Y/Bk 53-54
O/Bk 128
O/Bk 127
R/W 125
P/R 69
R/W 101
P/R 67-68
W/Bk 98
Bk/W 64
Bk/G 66
P/Y 143
Bk/R 65
V 100
B 133
Y/Bk 52
Y/Bk 52
O/G 40
G/O 86
O/G 43
O/G 40
O/G 41
O/G 42
R/G 10
Bk 129
B 27
P/R 74
P/R 75
P/R 76
P/R 77
P/R 67
B/R 48
O/G 44
O/G 45
B 18
O 122
P/R 68
P/R 69
O 102
Bk 93
Bk 94
Bk 63
B 21
R 2
R 6
R 4
R 5
36 1
2
R/Bk 115
B 29
R/Bk 116
B 25
1
2 3
3 B 39
4 B 30
4
ELLIPTICAL MODULE
Lb 119 1
B 23 2
1 W 154
BIFUNCTION CARD
18
1 B/Y 177
7
2
3 B 33 G 103
W/Br 114
B 22
38
11 B/Y 136 B 17 16_M
9 R/B 121
8 Bk 117 Br 59 8_M
14 R 161 Br/W 60 46_M
15 Bk 160 Br/Bk 61 34_M
7 V 100 Br/G 62 45_M
1 R9 R7 52_M
10 P 85 R/Y 149 25_M
O/B 12 58_V
47_M
V/Bk 83 37_M
O/G 46 40_M
46 Y/R 11
R/Y 151
Gy 57
78_V
63_V
2_M 1
41
Gy/B 58 1_M
B/Y 137 B 16 5_M
44_M
Gr 79 R/Bk 107 32_M
76_V
Gy/B 108 14_M
W 95 35_M
Gy/Y 109 70_V
G/O 86 73_V
W/Bk 98 61_V
Br 96 20_M
R/W 125 31_M
Br/G 110 12_M
54_V
O/Y 13 69_V
Y/G 152 72_V
Bk/V 88 65_V
40 1
2
Lb 118
B 32
Bk/W 92 56_V
Br/Bk 61
Br/W 60
Br/G 62
Gy 105 10_M
P/R 71
Br 59
P/R 73
G 106 22_M
O/Bk 141
Bk 63 53_V
W 154
Bk/W 92
O-W 81
B 14-15-16-17-18-35
Gr 79
B 99
Bk/W 64 67_V
B 34
B/Gr 174
O 122
B/Y 173
2 1 3 5 4 6 Bk/G 66 68_V
B/Y 139
Br 96
G/W 80
W 95
B175
97
Bk/R 65 74_V
42
Br/Bk 169
Br/W 167
Gy/Bk 55
Br/G 170
P/R 165
Br/G 110
P/R 168
Gy/G 56
Gy/B 58
Br 166
P/Y 146
B P/Y 147
B/R 51
B/R 50
B/R 49
B/R 48
R/Y 149
P/Y 145
Gy 57
P/Y 144
Bk/V 88
W/G 87
O/G 47
B 38
B 37
B 36
B 35
Gy/B 108
TEMP.
A V/Bk 83 Y/B 90 80_V
3 2 1 5 3 7 6 8 9 10 4 1 O/Bk 91 66_V
B 70
R3
1 2 3
F8
R/Y 151
B14
P/Y 148
R1
W/R 82
1 2
P 85
171
172
Gy
Bk
Lb
Bk/B
R/B
P/R
O/Y 13
W
R1
1 2 1 2 1 2 1 2 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 2 1 1 2
B/W
B/Gr
B/Y
B
40 A
B A C
48
1 2 3 2 3 1
B
LO
O/Bk 163
PASSING
B/Y 164
Y/B 162
1 2 3 4 B/Y 140 3 1 4 5 6
C
B
HORN
B 15
HI
R 2-3 40 A
51
TURN
PRESS.
53 F9 5
OK SET
5 6 7 8
49 50 52 9 10
27 22 23 24 25 26 19 17
2 3 4 1
65
28 39 43
65
13 14 15 16 12 55 54
-7-
Electrical system
E
12 R.p.m. sensor 44 Relay ballast headlight
13 Coil 45 Exhaust valve actuator
14 Coil 46 Immobilizer Antenna
15 Coil 47 Fan relay
16 Coil 48 Battery recharge
17 Alternator 49 Clutch switch
18 Speed sensor 50 Starter motor
19 Solenoid starter 51 Engine earth
20 General feed relay 52 Voltage regulator
21 Intermittence 53 TSS valve
22-23 Upper injectors 54 Additional CAN socket
24-25 Upper injectors 55 Angular switch
26 Throttle potentiometer 56 Secondary air system
27 Water temperature sensor – CPU 57 Lambda sensor
28 Oil switch 58-59 Lower injectors
29 Electric fan 60-61 Lower injectors
30 Fuses
31 Electric fan
32 Side stand switch
33 Rear stop switch
-8-
Electrical system
35 34 28 30 44 6 20 47 30 18 26 39 42 33 67 27 12 8 54 32 62 63 29 31 21
R R/G Gy/R B/Y
LOCK
START
RUN
OFF
OFF
ON
DOWN
PUSH
UP
FREE
+ - S
6
5
G
4
7.5A
7.5A
3
15A
15A
15A
15A
15A
2
N
Bk
1
Br/Bk
Br/W
G/W
PRESS. + -
Br
R/Y
G/Y
Y/G
R/G
Y/G
Y/G
O
B
A
3 1 2 6 5 4 3 2 1 4 1 3 2 1 4 2 3 1 5 6 7 8 1 2 2 1 1 2 1 2 1 2 3 1 3 2 1 2 3 1 2 4 1 3 1 2 1 2 1 2 3 4 5 6 7 8 9 10 11 12
O-Bk
O-Bk
R-Bk
R-Bk
R-Bk
Bk-Y
Bk-Y
O-Gr
Gr-O
Y-Bk
Y-Bk
W-R
Gr-B
Y-Bk
Gr-O
Gr-W
Y-Bk
B-Bk
B-Bk
Y-Bk
B-Bk
Y-Bk
W-O
W-R
Br-B
Sb-Bk
Bk-Y
Y-Bk
R-W
Y-Bk
Y-Bk
Br-P
R-W
R-W
R-W
B-O
O-B
O-V
R-W
B-W
B-W
B-W
R-W
R-B
Y-B
Bk-R
P-R
Y-V
Y-B
Y-B
Br-Y
R-Y
Bk-R
P-R
Y-Bk
Gy
Br-Gr
Sb
Br-Bk
Br-Bk
Bk
Gr
Sb
Sb
Sb
Gr
Bk
R
Gr-W
Br
B
O
B
R
B
P
R
B
B
O
R
E
40
R A1 IN_REL +
1 Sb W A2 IN_REL -
2 B
36 A3
1 R-Bk IN_CAMSHAFT
2 B Br-Y A4 IN_GEAR_POS
V-Gr B1 IN_THROTTLE_POS_1A
R-V B2 IN_THROTTLE_POS_2A
37
BIFUNCTION CARD
R-Gr C1 IN_LAMBDA_1
ELLIPTICAL MODULE
B-Bk C2 IN_GASPOS_3
1 Br-W W-R C3 IN_INTAKE_PRES_1
BALLAST 5 P-R C4 Roll Angle Sensor (ABS)
gnd
3 B Br-P D1 IN_WATER_TEMP
Br-B D2 IN_AIR_TEMP
Gr-O D3 IN_TSS_FBK
DL
2 Br-Bk O D4 IN_EXHAUST_FBK
Bk E2 IN_SEC_CURRENT
gnd
R E3 IN_SEC_CURRENT
Gr E4 IN_SEC_CURRENT
55
W E1 IN_SEC_CURRENT
2 B W-Bk F1 OUT_INJECTOR_1A
DL
1 Br-Bk Br-V F2 OUT_INJECTOR_2A
W-P F3 OUT_INJECTOR_3A
Br-Gy F4 OUT_INJECTOR_4A
4 B-Bk Gr-Bk G1 OUT_INJECTOR_1B
3 B-W Gr-P G2 OUT_INJECTOR_2B
16 Br-Y Gy-R G3 OUT_INJECTOR_3B
5 Gr Br-V G4 OUT_INJECTOR_4B
2 B V H1 OUT_H_LAMBDA_1
H2
38
6 Br-W OUT_H_LAMBDA_2
11 Y-Bk H3 OUT_VVT_VALVE
9 Sb-Bk Y-B H4 GND Analog
Gr J1 GND Analog
14 Bk Bk J2
1
GND Analog
15 Bk Y-Bk J3 GND Analog
7 V Br J4 GND Analog
1 R O-B K1 VREF_1
10 P Y-P K2 VREF_1
8 Y-Bk Y-Gr K3 VREF_2
Y-V K4 VREF_2
Gr-Bk L1 OUT_BRIDGE_A1
Br L2 OUT_EXHAUST_VALVE_A
46
P L4 OUT_IGN_COIL_2
2 Bk W-Br M4 OUT_IGN_COIL_3
1 Bk Gy-Bk M1 OUT_BRIDGE_B1
Y M2 OUT_EXHAUST_VALVE_B
L3
2
O-Bk OUT_IGN_COIL_1
1 Br-Bk P-R M3 OUT_IGN_COIL_4
2 B B-O A1 IN_SPD_FRONTW
W-O A2 IN_SPD_REARW
Gr-O A3
7
IN_START_SW
2 Gr B-W A4 IN_SIDE_STAND
1 Br-Bk Gy-Gr B1 IN_CLUTCH_SW
3 B R-Y B2 IN_RUN_STOP
B3 IN_TIP_OVER
Gy B4 IN_GAS_POS_1
O-V C1 IN_GAS_POS_2
P-R C2 OUT_PUMP_RELAY
R-B C3 OUT_LOW_BEAM
Gr-B C4 OUT_FAN_RELAY_1
D1 OUT_FAN_RELAY_2
41
Gr-W D4 MAIN_SWITCH_(KL15)
Gy Br-Bk E1 GND Analog
Y-Bk Sb E2 GND Analog
O-Bk F1 VREF_1
Br-Gr E4 VREF_2
B-W F3 COMM_CAN_H1
B-Bk F4 COMM_CAN_L1
G1 OUT_AIRCUT_VALVE
G2 OUT_CANISTER
O-V G3 OUT_TSS
Br-W G4 OUT_STARTER_RELAY
Gr H1 OUT_REAR_STOP
R H2 POWER_BATTERY_(KL30)
3
B H3 GND Power (KL31)
1 R-Bk B H4 GND Power (KL31)
2 B
4
1 Sb
2 B
F1 F2 F3 F4 F5 F6 F7
Br-Gy
W-Bk
W-P
Br-V
O-Gr
F8
Gy-Bk
Gr-Bk
Gy-Gr
Br-Bk
Br-W
Gr-Bk
Gr-Bk
O-Bk
B-Bk
B-W
Y-Bk
Y-Bk
Y-Bk
O-Y
O-V
R-Bk
Gy-R
Gr-P
7.5A
7.5A
O-Bk
W-Br
B
O-Gr
Y-Bk
B-Bk
Y-Bk
Br-V
O-Gr
O-Gr
O-Gr
O-Gr
15A
15A
R-Gr
Y-Bk
Br-W
W-R
W-R
Br-Y
Y-Gr
V-Gr
W-R
W-R
15A
15A
B-W
15A
R-V
P-R
W-R
Y-B
Y-P
Sb
Gy
Gr
Bk
Bk
W
Br
B
R
R
O
B
B
P
B
B
B
R
Y
Y
Y
Y
Y
Y
Y
V
B
R
R
B
B
V
66
40 A
3 2 1 3 2 1 5 3 7 6 8 9 10 4 1 B C A D E 3 2 1 4 2 1 1 4 3 2 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 3 2 1 2 1
B
2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1
3 1 4 5 6
40 A
51
Lb
Gy
Bk
R/B
P/R
Bk/B
4 3 2 1
F9
B/W
B
B/Gr
B/Y
56 5 45 64 65 53 11 19 50 52 48 9 10
LO
HORN
TURN
PASSING
7 6 5 8 4 3 2 1
30
HI
OK SET
49 17
68 43 25 24 23 22 61 60 59 58 16 15 14 13 57
-9-
Electrical system
E
12 R.p.m. sensor 46 Immobilizer Antenna
13 Coil 47 Fan relay
14 Coil 48 Battery recharge
15 Coil 49 Clutch switch
16 Coil 50 Starter motor
17 Alternator 51 Engine earth
18 Rear speed sensor 52 Voltage regulator
19 Solenoid starter 53 TSS valve
20 General feed relay 54 Front speed sensor
21 Intermittence 55 Position lights
22-23 Upper injectors 56 Quick Shift
24-25 Upper injectors 57 Lambda sensor
26 Throttle potentiometer 58-59 Lower injectors
27 Water temperature sensor – CPU 60-61 Lower injectors
28 Oil switch 62 TPMS connection
29 Electric fan 63 Lean angle sensor
30 Fuses 64 DBW (Drive by Wire) position
31 Electric fan 65 DBW (Drive by Wire) actuator
32 Side stand switch 66 Suspension management unit
33 Rear stop switch (only for F4 RR)
34 Ignition switch 67 Water temperature sensor – Fan
35 Safety and Front stop switch 68 SET/OK button
- 10 -
Electrical system
35 34 28 30 44 6 20 47 30 26 39 42 33 67 27 12 8 32 62 63 29 31 21 69 18 54
LOCK
R R/G Gy/R B/Y
F10 F11
START
RUN
OFF
OFF
ON
DOWN
PUSH
UP
FREE
+ - S
6
5
G
4
7.5A
7.5A
3
15A
15A
15A
15A
15A
15A
25A
2
N
Bk
1
Br/Bk
Br/W
G/W
Br
PRESS. + -
R/Y
G/Y
Y/G
Y/G
Y/G
R/G
O
B
A
B
A
B
3 1 2 6 5 4 3 2 1 4 1 4 2 3 1 5 6 7 8 1 2 2 1 1 2 1 2 1 2 3 1 2 3 1 2 4 1 3 1 2 1 2 1 2 3 4 5 6 7 8 9 10 11 12 11 2 3 4 9 10 1 12 13 14 18 2 1 2 1
O-Bk
O-Bk
Gr-O
O-Gr
O-Bk
O-Bk
Y-Bk
Gr-O
W-R
Gr-B
B-Bk
Gr-W
R-Bk
R-Bk
R-Bk
W-R
Bk-Y
Bk-Y
Br-B
W-O
B-Bk
Y-Bk
Y-Br
W-O
R-W
Y-Bk
Y-Bk
Y-Bk
Y-Bk
O-B
O-V
Br-P
Y-Br
R-W
B-O
Bk-Y
B-W
B-Bk
Y-Bk
B-Bk
Y-Bk
R-Y
R-W
Sb-Bk
R-W
R-B
B-Y
R-W
R-W
Y-B
B-Y
B-Y
B-O
Y-V
Y-B
Y-B
B-Y
Bk-R
P-R
Bk-R
B-W
B-W
B-W
P-R
Gy
Br-Gr
Y-Bk
Sb
Br-Y
Gr
Br-Bk
Bk
Gr-W
Gr
R
W
Br
Sb
Sb
Sb
W
O
R
R
P
R
B
B
B
B
B
B
B
O
R
R
E
A1
40
R IN_REL +
1 Sb W A2 IN_REL -
2 B
36
1 R-Bk A3 IN_CAMSHAFT
2 B Br-Y A4 IN_GEAR_POS
V-Gr B1 IN_THROTTLE_POS_1A
R-V B2 IN_THROTTLE_POS_2A
37
BIFUNCTION CARD
R-Gr C1 IN_LAMBDA_1
ELLIPTICAL MODULE
B-Bk C2 IN_GASPOS_3
1 Br-W W-R C3 IN_INTAKE_PRES_1
BALLAST 5 P-R C4 Roll Angle Sensor (ABS)
gnd
3 B Br-P D1 IN_WATER_TEMP
Br-B D2 IN_AIR_TEMP
Gr-O D3 IN_TSS_FBK
DL
2 Br-Bk O D4 IN_EXHAUST_FBK
Bk E2 IN_SEC_CURRENT
gnd
R E3 IN_SEC_CURRENT
Gr E4 IN_SEC_CURRENT
55
W E1 IN_SEC_CURRENT
2 B W-Bk F1 OUT_INJECTOR_1A
DL
1 Br-Bk Br-V F2 OUT_INJECTOR_2A
W-P F3 OUT_INJECTOR_3A
Br-Gy F4 OUT_INJECTOR_4A
4 B-Bk Gr-Bk G1 OUT_INJECTOR_1B
3 B-W Gr-P G2 OUT_INJECTOR_2B
16 Br-Y Gy-R G3 OUT_INJECTOR_3B
5 Gr-Bk Br-V G4 OUT_INJECTOR_4B
2 B V H1 OUT_H_LAMBDA_1
H2
38
6 Br-W OUT_H_LAMBDA_2
11 Y-Bk H3 OUT_VVT_VALVE
9 Sb-Bk Y-B H4 GND Analog
Gr J1 GND Analog
14 Bk Bk J2 GND Analog
Bk J3
1
15 Y-Bk GND Analog
7 V Br J4 GND Analog
1 R O-B K1 VREF_1
10 P Y-P K2 VREF_1
8 Y-Bk Y-Gr K3 VREF_2
Y-V K4 VREF_2
Gr-Bk L1 OUT_BRIDGE_A1
Br L2 OUT_EXHAUST_VALVE_A
L4
46
P OUT_IGN_COIL_2
2 Bk W-Br M4 OUT_IGN_COIL_3
1 Bk Gy-Bk M1 OUT_BRIDGE_B1
Y M2 OUT_EXHAUST_VALVE_B
L3
2
O-Bk OUT_IGN_COIL_1
1 Br-Bk P-R M3 OUT_IGN_COIL_4
2 B A1 IN_SPD_FRONTW
A2 IN_SPD_REARW
Gr-O A3
7
IN_START_SW
2 Gr B-W A4 IN_SIDE_STAND
1 Br-Bk Gy-Gr B1 IN_CLUTCH_SW
3 B R-Y B2 IN_RUN_STOP
B3 IN_TIP_OVER
Gy B4 IN_GAS_POS_1
O-V C1 IN_GAS_POS_2
P-R C2 OUT_PUMP_RELAY
R-B C3 OUT_LOW_BEAM
Gr-B C4 OUT_FAN_RELAY_1
D1 OUT_FAN_RELAY_2
41
Gr-W D4 MAIN_SWITCH_(KL15)
Gy Br-Bk E1 GND Analog
Y-Bk Sb E2 GND Analog
O-Bk F1 VREF_1
Br-Gr E4 VREF_2
B-W F3 COMM_CAN_H1
B-Bk F4 COMM_CAN_L1
G1 OUT_AIRCUT_VALVE
G2 OUT_CANISTER
O-V G3 OUT_TSS
Br-W G4 OUT_STARTER_RELAY
Gr H1 OUT_REAR_STOP
R H2 POWER_BATTERY_(KL30)
H3
3
B GND Power (KL31)
1 R-Bk B H4 GND Power (KL31)
2 B
4
1 Sb
2 B
F1 F2 F3 F4 F5 F6 F7
Br-Gy
W-Bk
W-P
Br-V
O-Gr
F8
Gr-Bk
Gy-Bk
Gy-Gr
Br-Bk
Br-W
O-Bk
Gr-Bk
Gr-Bk
B-Bk
B-W
Y-Bk
Y-Bk
Y-Bk
O-Y
R-Bk
O-V
Gy-R
Gr-P
O-Bk
W-Br
O-Gr
Y-Bk
B-Bk
B
R-Gr
Y-Bk
O-Gr
O-Gr
O-Gr
Br-W
Br-V
O-Gr
Y-Bk
Br-Y
W-R
W-R
Y-Gr
V-Gr
W-R
W-R
B-W
R-V
P-R
W-R
Y-B
Y-P
Sb
Gy
Gr
Bk
Bk
W
Br
B
R
R
B
O
B
P
B
B
B
R
Y
Y
Y
Y
Y
Y
B
V
B
B
V
R
B
66
40 A
3 2 1 3 2 1 5 3 7 6 8 9 10 4 1 B C A D E 3 2 1 4 2 1 1 4 3 2 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 3 2 1 2 1
B
7.5A
7.5A
2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1
15A
15A
15A
15A
15A
3 1 4 5 6
40 A
51
Lb
Gy
Bk
R/B
P/R
Bk/B
4 3 2 1
F9
B/W
B
B/Gr
B/Y
56 5 45 64 65 53 11 19 50 52 48 9 10
LO
HORN
TURN
PASSING 7 6 5 8 4 3 2 1
HI
OK SET
49 17 30
68 43 25 24 23 22 61 60 59 58 16 15 14 13 57
- 11 -
Electrical system
E
12 R.p.m. sensor 47 Fan relay
13 Coil 48 Battery recharge
14 Coil 49 Clutch switch
15 Coil 50 Starter motor
16 Coil 51 Engine earth
17 Alternator 52 Voltage regulator
18 Rear speed sensor 53 TSS valve
19 Solenoid starter 54 Front speed sensor
20 General feed relay 55 Position lights
21 Intermittence 56 Quick Shift
22-23 Upper injectors 57 Lambda sensor
24-25 Upper injectors 58-59 Lower injectors
26 Throttle potentiometer 60-61 Lower injectors
27 Water temperature sensor – CPU 62 TPMS connection
28 Oil switch 63 Lean angle sensor
29 Electric fan 64 DBW (Drive by Wire) position
30 Fuses 65 DBW (Drive by Wire) actuator
31 Electric fan 66 Suspension management unit
32 Side stand switch (only for F4 RR)
33 Rear stop switch 67 Water temperature sensor – Fan
34 Ignition switch 68 SET/OK button
35 Safety and Front stop switch 69 ABS Unit
36 Front right indicator
Wiring colour code Fuses list
- 12 -
BATTERY
The battery mounted on this motorcycle is a sealed
battery therefore no maintenance is required.
INITIAL CHARGE
Charge the battery using the current and charging time
shown on the battery itself.
To avoid overcharging the battery, we recommend
using the constant voltage charging method as speci-
fied in the table below:
- 13 -
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Electrical system
BATTERY ASSEMBLY
1) Perform the initial charge of the battery according to
the instruction shown in page 13.
- 14 -
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Electrical system
- 15 -
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Electrical system
Wait at least twenty-four hours before positioning the battery in the compartment.
This is strictly necessary for this motorcycle as the battery is positioned horizontally, as shown
in the diagrams below.
- 16 -
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Electrical system
BATTERY RECHARGE
The battery is charged by connecting the supplied bat-
tery charger to the connector located under the pas-
senger seat. If the battery is charged after a period of
vehicle downtime, make sure that the charger fuse is
placed inside its housing on the remote ignition switch.
Put the motorcycle key inside the rear lock. Turn the
key clockwise and at the same time turn the passenger
seat.
Take out the rubber cap (1) for the charger connector. 1
- 17 -
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Electrical system
CHARGING SYSTEM
Warning function
VOLTAGE REGULATOR
- 18 -
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Electrical system
A list of possible problems that could occur when the warning light is switched on.
YES
YES
E
PROBLEMS OCCUR
YES
RESTORE OR CLEAN CON- WARNING LIGHT STILL ON
WITH CONNECTION NECTION
NEGATIVE ON BATTERY
YES
- 19 -
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Electrical system
E
Battery current loss: less than 1mA.
If losses are found, search for the part where the tester
measures less than 2÷2.5mA by removing couplings
and connectors one at a time. Red lead Black lead
- 20 -
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Electrical system
Feed charge
Standard: 12.6V – 14.5V at 2000 r.p.m.
STARTER SYSTEM
The diagram below represents the starter system.
- 21 -
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E
F4 MY10 -> MY12
SAFETY SWITCH
Ignition key in the “ON” position SOLENOID
KEY SWITCH STARTER
SERVICE FUSE
MAIN RELAY
INJECTOR FUSE
FULE PUMP,
INJECTORS RELAY
FUEL PUMP - COILS -
SWITCH SWITCH
BATTERY
Start activated
Side stand out
Gear not engaged
Clutch not pulled in
Engine is starting
- 22 -
TILT SENSOR
Electrical system
PLUG-TOP
COILS
PRESSURE SENSOR
THROTTLE BODY UNDER THROTTLE
UPPER INJECTRS
PICK-UP WHEEL SIDE STAND SWITCH
THROTTLE BODY
LOWER INJECTRS
F4 MY10 -> MY12
SAFETY SWITCH
Ignition key in the “ON” position SOLENOID
Safety switch in the “RUN” position KEY SWITCH STARTER
SERVICE FUSE
MAIN RELAY
INJECTOR FUSE
FULE PUMP,
INJECTORS RELAY
FUEL PUMP - COILS -
SWITCH SWITCH
Start activated
BATTERY
Side stand out
Gear engaged
Clutch pulled in
Engine is starting
- 23 -
Electrical system
TILT SENSOR
PLUG-TOP
COILS
PRESSURE SENSOR
THROTTLE BODY UNDER THROTTLE
UPPER INJECTRS
PICK-UP WHEEL SIDE STAND SWITCH
THROTTLE BODY
LOWER INJECTRS
E
E
F4 MY10 -> MY12
SERVICE FUSE
Start activated
MAIN RELAY
INJECTOR FUSE
FULE PUMP,
INJECTORS RELAY
FUEL PUMP - COILS -
Side stand out SWITCH SWITCH BATTERY
Gear NOT engaged
Clutch pulled in
Engine is starting
- 24 -
Electrical system
TILT SENSOR
PLUG-TOP
COILS
PRESSURE SENSOR
THROTTLE BODY UNDER THROTTLE
UPPER INJECTRS
PICK-UP WHEEL SIDE STAND SWITCH
THROTTLE BODY
LOWER INJECTRS
SOLENOID
NEUTRAL
SAFETY SWITCH
CLUTCH STARTER
SWITCH SWITCH
F4 MY13
KEY SWITCH
MAIN RELAY
Ignition key in the “ON” position
Safety switch in the “RUN” position
Start activated
BATTERY
Side stand out
Gear not engaged
Clutch not pulled in
Engine is starting
LEAN
SENSOR
- 25 -
Electrical system
THROTTLE BODY
UPPER INJECTRS
PLUG-
TOP
COILS
THROTTLE BODY
LOWER INJECTRS
PRESSURE
SENSOR
UNDER
THROTTLE
PICK-UP SIDE
WHEEL STAND
SWITCH
E
E
SOLENOID
NEUTRAL CLUTCH SAFETY SWITCH STARTER
SWITCH SWITCH
F4 MY13 KEY SWITCH
MAIN RELAY
Ignition key in the “ON” position
Safety switch in the “RUN” position
Start activated
BATTERY
Side stand out
Gear engaged
Clutch pulled in
Engine is starting
LEAN
SENSOR
- 26 -
Electrical system
THROTTLE BODY
UPPER INJECTRS
PLUG-
TOP
COILS
THROTTLE BODY
LOWER INJECTRS
PRESSURE
SENSOR
UNDER
THROTTLE
PICK-UP SIDE
WHEEL STAND
SWITCH
SOLENOID
NEUTRAL CLUTCH SAFETY SWITCH STARTER
SWITCH SWITCH
F4 MY13 KEY SWITCH
MAIN RELAY
Ignition key in the “ON” position
Safety switch in the “RUN” position
Start activated
BATTERY
Side stand out
Gear NOT engaged
Clutch pulled in
Engine is starting
LEAN
SENSOR
- 27 -
Electrical system
THROTTLE BODY
UPPER INJECTRS
PLUG-
TOP
COILS
THROTTLE BODY
LOWER INJECTRS
PRESSURE
SENSOR
UNDER
THROTTLE
PICK-UP SIDE
WHEEL STAND
SWITCH
E
Electrical system
F4 MY13
- 28 -
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Electrical system
E
F4 MY10 -> MY12
F4 MY13
- 29 -
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Electrical system
- 30 -
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Electrical system
LEAN SENSOR (MY13)
The lean sensor (1) detects the acceleration values
and sends them to the engine control unit, which inter-
venes on the engine working by adjusting the traction
control. Besides, it interrupts power when a vehicle tilt
of more than 65° is detected. 1
- 31 -
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Electrical system
- 32 -
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Electrical system
FUSES
The fuses are situated on the left side of the motorcy-
cle.
Lift the rubber cover.
7.5A
15A
15A
15A
15A
15A
- 33 -
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Electrical system
SPARK PLUGS
Remove the components of the motorcycle to remove
the spark plugs as described in chapter B “Mainte-
nance”.
- 34 -
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Electrical system
MAIN RELAY
F4 MY13
Apply 12V to the terminals (1) and (3) and check the
continuity between terminals (4) and (2). If there is no
continuity, substitute the relay with a new one.
- 35 -
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Electrical system
ENGINE PICK-UP
The engine pick-up is situated on the left side of the
motorcycle. To check this component it is necessary to
identify the relative connector positioned as shown in
the figure, inside the frame on the left side of the motor-
cycle.
E
F4 MY13
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F4 MY13
F4 MY13
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F4 MY13
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Electrical system
WATER SENSOR
Verify sensor operation by measuring resistance
between the pin by means of a tester.
MY13:
Ub = 5 V +/- 10%
Rv = 2000 Ω +/- 1%
TEMP. °C RESIST. Ω TEMP. °C RESIST. Ω
- 40 104442,9 + 50 1016,9
- 30 53932,5 + 60 703,8
- 20 29050,7 + 70 496,7
- 10 16266,4 + 80 356,9
0 9439,2 + 90 260,7
+ 10 5661,8 + 100 193,3
+ 20 3501,9 + 110 145,6
+ 30 2264,5 + 120 111,1
+ 40 1500,7 + 125 97,5
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Electrical system
KEY SWITCH
Whenever the dashboard, with the switch on the ON
position, is not powered, first check the conditions of
the fuse located on the start-up remote switch under
the seat and, if this should be in good condition, check
the conditions of the fuse located in position 1 on the
fuse box.
TURN INDICATORS
If the blinker warning lights do not work, continuity
must be checked on the cable R-B between terminal 7
of the switch connector and terminal 9 of the dash-
board connector.
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Electrical system
INTERMITTENCE RELAY
The intermittence relay (1) is placed on the front part of
the motorcycle, upon the central conveyor.
DIAGNOSTICS UNIT
The diagnostics connector (2) is placed under the pas-
senger’s saddle.
LAMBDA SENSOR
The lambda sensor (3) is placed on the right side of the
exhaust manifolds.
Its working is completely controlled by the ECU.
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Electrical system
ABS* UNIT (MY13)
The unit of the ABS system (1) is placed under the pas-
1
senger’s saddle.
SPEED SENSOR
Whenever the speed is not indicated on the dashboard
and the message SPEED SENSOR appears, proceed
as follows:
• Check the conditions of the fuse in position 1 on the
fuse box.
If the above fuse is in good condition, proceed with the
check of the speed sensor as follows:
Keeping the sensor connected to the system and with
the key in the ON position, using a tester, check that
when the sensor is positioned in front of one of the nuts
of the brake disk, between terminal 3 and terminal 2 of
the connector, the voltage is close to zero, whilst when
it is not placed in front of one of the nuts, the voltage is
close to that of the battery.
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Electrical system
MY13:
In the event that the dipping beam does not work,
F4 MY13
check the conditions of fuse 2 on the fuse box. If this
fuse is ok, check the conditions of the relay placed on
the left side of the motorcycle, with the label "B".
F4 MY13
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TURN INDICATORS
In the event that turn indicators do not work, check the
conditions of following fuse:
LICENCE PLATE LIGHT
If the number plate light bulbs do not function, check
the condition of fuse 1 in the fuse box; if these are ok,
replace the bulb by following the procedure described
in Section B - Maintenance.
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Electrical system
HORN
- 47 -
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Electrical system
SWITCHES
Check the continuity of each switch with a tester. If there is any anomaly, substitute the respective switch unit with
a new one.
R.H. switch
L.H. switch
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Electrical system
Note: Be careful
to correctly pass
the Pierburg valve tube
- 49 -
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Electrical system
Insert 1 protective clamp (Code 8000B4230) on the throttle body clamps present on the right
side of the motorcycle (see Fig. 03).
Protective clamp
Code 8000B4230
E
Note: Be careful
to correctly position the
node and the TPS cable
Code
Code Code
Code
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Electrical system
Note: Be careful
to correctly pass
cables
Code
Code
Note: Be careful
to correctly pass
cables
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Electrical system
Code Code
Code
Note: Be careful
to correctly pass
cables and the blow-by hose
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Code
Note the correct passage of vacuum gauge tubes on both the left and right sides of the
motorcycle (see figs. 09-10).
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Electrical system
- Position 1 adhesive protection code 8000B4924 on the front right side frame tube, first
applying the upper edge as shown in Fig.11.
Protection
(Code. 8000B4924)
- Wrap the adhesive protection around the frame tube and complete application taking care to
stretch it evenly to avoid air bubbles (see Fig. 12).
- Apply 1 adhesive protection code 8000B4924 on the front left side frame tube in the same
way as described above for the right side tube.
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Electrical system
Note: be
careful to correctly
pass cables
- 55 -
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Electrical system
Code
Note: Be careful
to correctly pass
cables
Note: Be careful
to correctly pass
cables Code
Note: Be careful to
correctly pass
cables
- 56 -
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Electrical system
Code
Code 800056783
(plastic)
Code
3-way rear
headlight AMP
connector
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Electrical system
Note: Be careful to
correctly pass
Code cables
Code
Protection Code
sheat
Code
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Electrical system
Note: Be careful
to correctly pass
cables
Note: Be careful
to correctly pass
cables
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Suspension and wheels
SECTION
Revision 2
F
-1-
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Suspension and wheels
SUMMARY
-2-
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Suspension and wheels
FRONT WHEEL
G
F
A
E
B
D
C
B
A
A B C D E F G
N· m 20 ÷ 22 (F4 S - FT 40 ÷ 44 (F4 S - FT
F4 R - F4 MY13) F4 R - F4 MY13)
Torque
19 (F4 RR) 60 ÷ 65 (F4 RR)
pressure
Kg· m
ft· lb
Operation
-3-
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Suspension and wheels
-4-
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Suspension and wheels
Open the terminals (1) and remove the wheel with its
spindle.
Loosen the two screws (2) on the fork foot on the left
side of the vehicle. Leave the screws partly tightened
to facilitate the removal and tthe subsequent refitting of
the axle.
-5-
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Suspension and wheels
3
Before substituting the bearings as indicated
above it is advisable to remove the brake
discs as indicated in chapter H “Brakes” to
avoid damaging them. 4
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Suspension and wheels
F
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.
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Suspension and wheels
F
Proceed as illustrated in the figure.
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Suspension and wheels
F4 S - FT - R
F4 RR
- F4 MY13
40÷42 N•m
- 11 -
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Suspension and wheels
A H
L G
F
B
H
A
E
D
C
D
E
A B C D E F G H I L M N
N· m 40 20 ÷ 22 20 8 ÷ 10 8 ÷ 9 16 ÷ 18 22 ÷ 24
Torque
pressure Kg· m
ft· lb
Operation
- 12 -
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Suspension and wheels
F
Remove the front wheel as described in the chapter
"FRONT WHEEL" for the vehicle model. 2
- 13 -
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Suspension and wheels
Stem removal
Slacken the screw (1) of the steering head and the
three screws (2) of the steering base.
During this phase, support the stem.
Slide out the stem, supporting it with both hands and
operating with caution so as not to drop it.
Proceed with the same operation for both stems.
1
- 14 -
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Suspension and wheels
F
Unscrew the plug. Using the spanner, adjust the spring
preload while locking the nut on the damping piston
rod.
- 15 -
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F
Lower dust cap (1), taking care not to damage the seat
on the sheath.
- 17 -
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Extract the fork leg with repeated jerks at the end of its
travel.
- 18 -
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Suspension and wheels
F
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.
- 19 -
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Suspension and wheels
Fit the inner rod and the spring spacer in their hous-
ings.
Recommended oil:
Marzocchi EBH16 SAE 7,5
- F4 S / FT / R / F4 MY13 (**): X = 70 mm
- 20 -
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Suspension and wheels
F
Fit the spanner to damping piston nut (1), pressing
down slightly on the spring.
- 21 -
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Suspension and wheels
F
Insert and screw in the complete cap (1) on the fork sli-
der.
- 22 -
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Suspension and wheels
- F4 S / FT / R / F4 MY13: X = 212 mm
- F4 RR: X = 219 mm
F
Screw in and tighten the three screws (1) at the base
of the steering.
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Suspension and wheels
8÷10 N•m
F
Replace the brake line holding clamps.
- 25 -
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Suspension and wheels
Spring preload
Spring preload
Compression damper
Rebound damper
F4 S - F4 FT - Type of set-up
F4 R MY12 - F4 MY13 On road On race track
Spring preload 2 turns 5 turns
Rebound damping 16 clicks 4 clicks
Compression damping 14 clicks 2 clicks
Type of set-up
F4 R MY13
On road On race track
Spring preload 3 turns 3 turns
Compression damper
Rebound damping 14 clicks 11 clicks
Compression damping 13 clicks 11 clicks
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Suspension and wheels
Compression damper
Rebound damper
Type of set-up
F4 RR MY12
On road On race track
Spring preload 12 turns 12 turns
Rebound damping 9 clicks 8 clicks Compression damper
Compression damping 11 clicks 11 clicks
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Suspension and wheels
Spring preload
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Suspension and wheels
STEERING ASSEMBLY
F
H
A
L
E
F
D L
B D
G
D
A B C D E F G H I L
N· m 120 ÷ 125 16 ÷ 18 8 ÷ 10 4÷6 22 ÷ 24 22 ÷ 24 8 ÷ 10 In contact
-F4 MY13) +10°
18 ÷ 22
Torque
(F4 RR)
pressure
Kg· m
ft· lb
270
Operation
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Suspension and wheels
F
Protect the steering head with padded material and
rest it over the dashboard.
2
1
- 31 -
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Suspension and wheels
Using the specific tool, loosen the ring nut of the stee-
ring spindle, supporting the base of the steering head
with a hand.
- 32 -
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Suspension and wheels
F
Remove the adjustment screw (1) of the frame head
steering sleeve, sustaining the frame head steering
sleeve at the lower part.
- 35 -
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Suspension and wheels
1
Torque pressure: 18 ÷ 20 N·m
- 36 -
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Suspension and wheels
8÷10 N•m
8÷10 N•m
- 42 -
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Suspension and wheels
16÷18 N•m 2
Type of set-up
F4 RR MY13 8÷10 N•m
Normal Sport Rain
Steering damper 10 clicks 10 clicks 10 clicks
Steering damper adjustment
(F4 S - F4 FT - F4 RR MY12 - F4 R - F4 MY13)
The standard adjustment is obtained by fully rotating
the knob counterclockwise. In this position the damper
Adjusting knob
offers the least resistance to the rotation of the stee-
ring. To suit the rider’s needs, the action of the damper
can be gradually increased by rotating the knob
clockwise.
Refer to the values contained in the table to adjust the
steering damper.
Type of set-up
F4 S - FT - R - F4 MY13
On road On race track
Steering damper 2 clicks 2 clicks
Type of set-up
F4 RR MY12
On road On race track F4 S - FT - F4 R F4 RR MY12
- F4 MY13
Steering damper 0 clicks 3 clicks
- 43 -
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Suspension and wheels
C D
A B C D E
N· m 40 ÷ 44 40 ÷ 44 40 ÷ 44 45 ÷ 50 70 ÷ 75
Torque
pressure Kg· m
ft· lb
243
Operation
- 44 -
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Suspension and wheels
F
Slacken the upper screw (1) of the shock absorber.
- 45 -
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Suspension and wheels
F
Remove nut (3) from the central rocker pin.
- 46 -
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Suspension and wheels
Lift the rocker and extract at the same time as the com-
plete shock absorber.
- 47 -
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Suspension and wheels
Rebound damping
hydraulic device
F4 S - FT - Type of set-up
F4 R MY12 - F4 MY13 On road On race track
Rebound damping 16 clicks 7 clicks
Compression damping
Compression damping (high speed) 0 clicks 6 clicks
hydraulic device (low speed)
Compression damping (low speed) 18 clicks 7 clicks
- 48 -
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Suspension and wheels
F
For further tests on the ball joints of rear
shock absorber attachments, it is neces-
sary to follow disassembly phases descri-
bed in this chapter.
Type of set-up
F4 RR MY12
On road On race track
Rebound damping 13 clicks 9 clicks
Compression damping 9 clicks 5 clicks
Type of set-up
F4 R MY13
On road On race track
Rebound damping 18 clicks 13 clicks
Compression damping 18 clicks 16 clicks
Rebound damping
Rear suspension adjustment hydraulic device
(F4 RR MY13)
For rear suspension adjustment, refer to the values
shown in the table below.
NOTE The adjustment of rebound and compres-
Compression
sion damping can be performed only by damping
operating the digital functions of the dash- hydraulic device
board. For the modification of these para-
meters, refer to the procedures described at
page 80 of Section B - “Maintenance”.
Type of set-up
F4 RR MY13
Normal Sport* Rain
Compression damping 17 clicks 6 clicks 22 clicks
Rebound damping 15 clicks 13 clicks 18 clicks
NOTE (*): To use the vehicle in this configura-
tion, MV Agusta suggests to increase
the rear suspension spring preload of 1
mm (see page 85 of this chapter).
- 49 -
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Suspension and wheels
F
When reassembling, it is necessary to apply special
product to the three screws and lightly screw them in.
Tighten the central screw first and then the other two to
the prescribed torque pressure.
40÷44 N•m
- 51 -
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Suspension and wheels
3
Connecting rod torque pressure 40 ÷ 44 N·m 2
Shock absorber torque pressure 40 ÷ 44 N·m 45÷50 N•m
Compensator assembly torque pressure 45 ÷ 50 N·m 40÷44 N•m
- 52 -
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Suspension and wheels
Footrest removal
Unscrew the two screws (1) of both footrest supports F
and remove them.
- 53 -
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Suspension and wheels
Silencers Removal
Remove the closing wiring cover on the heat guard,
levering with a screwdriver.
- 54 -
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Suspension and wheels
F
Remove the fixing screw (1) of the exhaust valve plate.
Loosen the lock nuts (2) of the valve opening and clo-
sing adjusters.
- 55 -
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F
Supporting the silencer unit in its rear part, remove the
two exhaust support side screws (1) (see figure).
- 57 -
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Suspension and wheels
Unscrew bolt (1) so that the tip is retracted into the hex
nut.
- 58 -
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Suspension and wheels
Unscrew shoulder bolt (2) until you can insert the chain
into the special tool. Position the chain breaker (1) so 2
that the ends of the chain pin can fit into the holes of
the hex nut and bolt (2).
F
Screw the bolt (1) until the pin is out of the chain plate
on the wheel side.
- 59 -
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Suspension and wheels
Check that the fork of the new connecting link fork has
an O-Ring installed on each pin.
Insert the new connecting link fork from the wheel side,
avoiding any contact with the pins in order not to remo-
ve the lubricant.
- 60 -
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Suspension and wheels
Pull the plate (4) to open the positioning rods (3), insert
the chain into the tool in correspondance of the first pin
to rivet an release the plate (4). The chain should be
correctly inserted into the tool and kept in place by rods
(3).
F
Slide punch (5) to contact the head of the pin to be rive-
ted.
- 61 -
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F
Connect both ends of the chain with the connecting
link, and press the connecting plate into the connecting
pins by hand.
Fit the punch and the plate holder on the tool as shown
in the picture.
- 63 -
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Suspension and wheels
Turn the pin holder by hand until the plate holder con-
tacts with the connecting link plate.
After the riveting of the pin, check that the head dia-
meter of both pins is equal to the following value:
- 64 -
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- 66 -
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Bearings overhaul
If it is necessary to substitute the bearings of the swin-
garm because of excessive play, operate as follows:
Remove the right and left spacer.
F
Remove the Seeger retaining ring on the right side of
the swingarm.
Remove the anti-dust seal on the left side.
Utilising the special tool, remove the two roller bearing
units.
- 67 -
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I
O
E M
B
A
A B C D E F G H I L M N O
N· m 30÷35 20÷22 45÷50 200÷220 28÷32 220÷240 140 25 8 5÷7 18 18÷20
Torque
pressure Kg· m
ft· lb
Operation 243 270 243 243 270
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• Torque wrench
• 55 mm polygonal spanner
F
Slacken the fixings (1) of the wheel hub.
- 71 -
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Suspension and wheels
Special tool:
Eccentric adjuster spanner N. 800092854
Spanner extension N. 800092855
F
Remove the wheel spindle nut (2) previously slacke-
ned and the spacer ring (4) underneath. 2
Remove the rear sprocket unit (3) and the spacer ring
(5) underneath.
- 72 -
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Suspension and wheels
F
Slacken the two screws (6) and remove the brake cali-
per (7).
- 73 -
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- 75 -
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20÷22 N•m
- 76 -
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Suspension and wheels
Extract the 5 spring drives (2) from the gear flange sup-
port (3) and assess its condition.
If the spring drives are worn, replace with new ones.
2 3
F
Check that the coupling bushes of the gear flange sup-
port (1) and the driving flange (2) do not show any
signs of excessive or uneven wear. 1
- 77 -
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Remove the 5 nuts (3) to free the crown (1) from the
crown flange (2). 1
2
Replace the crown.
- 78 -
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Suspension and wheels
F
Grease the roller bearing.
Introduce the first bush, the spacer and then the
second bush.
- 79 -
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Suspension and wheels
F
Reinsert the rubber clamp (1) around the rear brake
pipe.
- 80 -
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Suspension and wheels
F
Reposition the nut of the flange (1) with the relative
washer (2) without tightening. 1
Special tool:
Spanner for eccentric hub N. 800092854
Extension for spanner N. 800092855
- 81 -
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Suspension and wheels
• Torque wrench
• 55 mm polygonal socket wrench
- 82 -
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Suspension and wheels
1
2
F
Remove the cover being careful to not extract the clut-
ch control rod (it must remain inserted in the engine)
and be careful to not lose the two centralising bushes
indicated in the figure.
- 83 -
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Suspension and wheels
- 84 -
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Suspension and wheels
F
Raise the rear part of the motorcycle until the full
extension of the rear shock absorber is reached.
Contemporaneously measure the distance X1 between
the upper extremity of the rear stand and the point on
the setting-up arm shown in the figure.
- 85 -
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Suspension and wheels
- 86 -
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Suspension and wheels
D = X1 – X2
The static settling value should be:
X2
- F4 S / FT / R MY12 / F4 MY13: D = 23 mm
- F4 RR MY12 / F4 R MY13: D = 22 mm
- F4 RR MY13: D = 23 mm
If static settling D differs from the above value, perform
the following adjustments on the shock absorber
spring.
- F4 RR MY12 / F4 R MY13:
Special tool:
Spanner No. 8000B7038
- F4 RR MY12 / F4 R MY13:
Special tool: F4 RR MY12 - F4 RR MY12 -
F4 R MY13: F4 R MY13:
Spanner No. 8000B7038 D < 22 mm D > 22 mm
D < 23 mm: Turn anticlockwise
D > 23 mm: Turn clockwise
- 87 -
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Suspension and wheels
- 88 -
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Suspension and wheels
F
Mount the wheel onto an adequate support similar to
that shown in the figure, utilising the special tool cod.
8000A1953. Check the wheel utilising a micrometer
gauge and check the following tolerances:
- 89 -
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Suspension and wheels
- 90 -
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Frame
SECTION
Revision 2
G
-1-
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Frame
SUMMARY
-2-
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Frame
BATTERY CABLES
It is a good rule to disconnect the battery
cables before removing components from the
motorcycle.
-3-
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Frame
-4-
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Frame
Remove the clamps and the tubes from the blade cov-
ers.
-5-
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Frame
-6-
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Frame
5÷7 N•m
-7-
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Frame
FOOTREST REMOVAL
Unscrew the two screws (1) of both footrest supports
and remove them.
-8-
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Frame
Loosen the lock nuts (2) of the valve opening and clos-
ing adjusters.
-9-
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Frame
- 10 -
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Frame
- 11 -
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Frame
- 12 -
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Frame
Unscrew the two screws (3), one per part, and remove
the front protection.
3
- 13 -
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Frame
Unhook the oil radiator from the rear support pin on the
engine to then facilitate removing the manifold.
- 14 -
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Frame
- 15 -
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Frame
- 16 -
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Frame
3 G
- 17 -
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Frame
G 6
- 18 -
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Frame
- 19 -
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Frame
- 20 -
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Frame
- 21 -
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Frame
G
5
- 22 -
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Frame
- 23 -
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Frame
- 24 -
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Frame
- 25 -
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Frame
- 26 -
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Frame
Connectors disassembling
- 27 -
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Frame
- 28 -
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Frame
- 29 -
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Frame
- 30 -
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Frame
Slip the wiring of the two connectors that you just dis-
connected behind the water pump tube and wind them
on the frame hook present on the left side of the motor-
cycle.
- 31 -
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Frame
Slightly lower the battery holder from the right side and
remove the rear frame electrical wiring.
- 32 -
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Frame
FRAME DISASSEMBLY
Unscrew and remove the right lower rear fixing nut
from the frame. Remove the spindle from the left side
of the frame.
- 33 -
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Frame
Remove the bushes from the rear right and left frame
fixing points with the aid of a special tool.
- 34 -
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Frame
- F4 S - FT - RR:
Carefully clean the coupling bevel housing of the steer-
ing sleeve.
- 35 -
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Frame
- F4 R - F4 MY13:
Carefully clean the seats of the steering bearings.
- 36 -
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Frame
- 37 -
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Frame
- 38 -
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Frame
- 39 -
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Frame
- 40 -
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Frame
- 41 -
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Frame
- 42 -
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Frame
- 43 -
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Frame
G
2 8000B3561 Upper engine mounting screw M12x1,25 55/60 5,5/6,0
- 44 -
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Frame
- 45 -
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Frame
- 46 -
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Frame
- 47 -
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Frame
- 48 -
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Frame
Loosen the fork spindle pivot nut from the right side of
the motorcycle.
Partially slide the fork spindle pivot off from the left side
of the motorcycle.
- 49 -
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Frame
- 50 -
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Frame
- 51 -
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Frame
Remove the fork pivot spindle from the left side of the
motorcycle.
24÷28 N•m
- 52 -
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Frame
- 53 -
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Frame
- 54 -
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Frame
- 55 -
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Frame
- 56 -
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Frame
- 57 -
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Frame
Protect the cover with a nylon cap and remove the two
wiring holding clamps.
- 58 -
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Frame
- 59 -
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Frame
- 60 -
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Frame
Extract the lower engine fixing spindle from the left side
of the motorcycle.
- 61 -
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Frame
- 62 -
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Frame
- 63 -
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Frame
G
engine on the vehicle, perform the following cable and
tubing positioning checks.
- 64 -
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Frame
- 65 -
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Frame
- 66 -
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Frame
Make sure the wiring on the right side follows the direc-
tion of the frame tubes.
- 67 -
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Frame
- 68 -
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Brakes
SECTION
Revision 2
H
-1-
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Brakes
SUMMARY
-2-
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Brakes
C F
D E
A
H
H
G
A B C D E F G H
N·m 2 8 8÷10 40 ÷ 42 23 ÷ 26 16 ÷ 18 8 ÷ 10 23 ÷ 25
Torque
Kg·m
pressure
ft·lb
243
Operation
It is advisable to remove the parts of the bodywork as described in the chapter "Bodywork" that could obstruct
normal operations, before proceeding with the overhaul of the front brake system.
-3-
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Brakes
Brake disc
Brake pads
-4-
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Brakes
Before fitting the pads back in, make sure the plate
rests against its stop. If it does not, push it down, as
shown in the Figure.
Fit either pad through the midst of the front back caliper
opening, then push it towards its pistons. Do the same
with the other pad.
40÷42 N•m
-5-
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Brakes
-6-
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Brakes
Fill the system by pulling the front brake lever 3-4 times
(see figure).
Repeat the above operations until the fluid reaches the
minimum level in the reservoir. Top up with fresh fluid
and carry on with the operation until fluid of a different
colour (fresh) flows out.
The quantity of brake fluid necessary for this operation
is approximately 250 cc.
-7-
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Brakes
-8-
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Brakes
Place the cap on the brake fluid tank and tighten the
two lateral fixing screws.
-9-
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Brakes
- 10 -
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Brakes
Fill the system by pulling the front brake lever 3-4 times
(see figure).
Repeat the above operations until the fluid reaches the
minimum level in the reservoir. Top up with fresh fluid
and carry on with the operation until fluid of a different
colour (fresh) flows out.
The quantity of brake fluid necessary for this operation
is approximately 250 cc.
Tighten the bleed screw, remove the rubber tube, care- 12÷16 N•m
fully clean the screw with alcohol, blow it dry and put the
protective cap back on.
- 11 -
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Brakes
- 12 -
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Brakes
Place the cap on the brake fluid tank and tighten the
two lateral fixing screws.
- 13 -
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Brakes
- 14 -
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Brakes
- 15 -
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Brakes
Remove the fixing screws that fix the pump to the han-
dlebar.
7÷9 N•m
Open the clamp.
Push down to remove the pump from the reference pin.
- 16 -
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Brakes
2
H
- 17 -
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Brakes
H 2
- 18 -
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Brakes
- 19 -
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Brakes
8÷10 N•m
- 20 -
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Brakes
For the reassembly of the lever, grease the pin with the
prescribed product.
5÷7 N•m
- 21 -
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Brakes
- 22 -
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Brakes
- 23 -
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Brakes
F
D
H E
A B C D E F G H
N·m 220 ÷ 240 15 ÷ 20 16 ÷ 18 8 ÷ 10 18 18 ÷ 20 16 ÷ 18
Torque
pressure Kg·m
ft·lb
Operation 243 270
- 24 -
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Brakes
- 25 -
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Brakes
Remove the pad support pin (1) and the relative spring
(2).
H Brake disc
Brake pads
- 26 -
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Brakes
15÷20 N•m
H
It is necessary to remove the seats, rear fairings and
fuel tank before performing these operations (see
chapter C "Superstructures").
Open the cover of the rear brake fluid reservoir by
removing the two screws (1).
- 27 -
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Brakes
- 28 -
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Brakes
Pay attention to the fluid left in the caliper and the tube.
- 29 -
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Brakes
Remove the clip with the pump control fork pin by turn-
ing the pin and pulling it out (see figure).
- 30 -
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Brakes
- 31 -
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Brakes
- 32 -
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Cooling system
SECTION
Revision 0
L
-1-
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Cooling system
SUMMARY
-2-
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Cooling system
Before proceeding with the disposal or overhaul of any component relative to the cooling system, carry out cer-
tain preliminary operations:
1) Let the engine cool down.
2) Remove the side fairings, the underfairing, the fairings push rod, the headlight fairing, the suction duct covers
and suction ducts as described in the chapter "Superstructures."
-3-
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Cooling system
-4-
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Cooling system
Wait until all the engine coolant has dripped out of the
cooling system.
RADIATOR DISASSEMBLY
-5-
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Cooling system
-6-
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Cooling system
-7-
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Cooling system
Lower the left side radiator and push it toward the right
to remove the upper support pin.
-8-
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Cooling system
-9-
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Cooling system
- 10 -
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Cooling system
- 11 -
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Cooling system
- 12 -
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Cooling system
- 13 -
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Cooling system
- 14 -
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Cooling system
- 15 -
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Cooling system
5÷6 N•m
- 16 -
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Cooling system
THERMOSTAT REMOVAL
- 17 -
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Cooling system
Check
Check to see if the thermostat pad is damaged.
Standard
Thermostat opening temperature:
60°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 raised up by at
least 7 mm.
Standard
Raising up of the thermostat:
More than 7.0 mm at 90°c.
• If the thermostat does not satisfy only one of the req-
uisites (opening temperature and raising up of the
thermostat), it must be substituted.
L
- 18 -
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Cooling system
THERMOSTAT ASSEMBLY
- 19 -
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Cooling system
L
10 N•m
Insert the upper right radiator mount into the peg on the
frame (right side).
- 20 -
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Cooling system
- 21 -
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Cooling system
- 22 -
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Cooling system
Remove the tube unions from the right side of the oil
radiator with the aid of a screwdriver.
- 23 -
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Cooling system
Lower the oil radiator from the left side and push
toward the right to free it from the support pin.
- 24 -
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Cooling system
- 25 -
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Cooling system
Max. level
Min. level
- 26 -
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Cooling system
MAX
MIN
35 N•m
- 27 -
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Cooling system
Cooling system
Insert the ignition key and start up the vehicle engine.
Keep it running until it warms up and wait until fans
enter into operation at least twice. Switch off the engi-
ne and wait for the temperature to cool down. Then do
a final check of the cooling liquid level and top up if
necessary.
- 28 -
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Special tools
SECTION
Revision 3
M
-1-
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Special tools
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.
-2-
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Special tools
-3-
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Special tools
-4-
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Special tools
1 Per catena di trasmissione Regina 525 ZRPK - For drive chain Regina 525 ZRPK - Pour chaîne de transmission Regina 525 ZRPK - Für
antriebskette Regina 525 ZRPK - Para cadena de transmisión Regina 525 ZRPK.
2 Per catena di trasmissione D.I.D. 525 HV2 - For drive chain D.I.D. 525 HV2 - Pour chaîne de transmission D.I.D. 525 HV2 - Für
antriebskette D.I.D. 525 HV2 - Para cadena de transmisión D.I.D. 525 HV2.
-5-
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Special tools
-6-
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Special tools
M
21 800095180 1 • • • • • Attrezzo Half-cones
montaggio assembling
semiconi tool
22 8000A2625 1 • • • • • Broccia per Broach for
guida valvole valve guide
23 8A00B2859 1 • • • • • Tubo Pipe
D39-d27,2-L74,5 D39-d27.2-L74.5
-7-
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Special tools
-8-
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Special tools
-9-
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Special tools
- 10 -
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Tightening torques
SECTION
Revision 3
N N
-1-
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Tightening torques
SUMMARY
-2-
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Tightening torques
-3-
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Tightening torques
-4-
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Tightening torques
-5-
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Tightening torques
-6-
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Tightening torques
-7-
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Tightening torques
-8-
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Tightening torques
-9-
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Tightening torques
- 10 -
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Diagnostic
SECTION
Revision 1
O
O
-1-
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Diagnostic
ELECTRICAL COMPONENTS
CHARGING SYSTEM
Battery warning light on Alternator broken Replace
Alternator connection defective Check
Voltage regulator connection defective Deoxidize/Repair
Voltage regulator broken Replace
Battery faulty Replace
Recharge fuse (40A) blown Replace
Recharge fuse connection defective Deoxidize/Repair
Battery connections oxidized Deoxidize/Repair
POWER SUPPLY FOR 12V SERVICES
No function enabled Ignition switch broken Replace
Ignition switch connection defective Deoxidize/Repair
Main relay broken Replace
Main relay connection defective Deoxidize/Repair
ELECTRIC STARTER
Electric starter does not work Start-up engine does not work, Tilt sensor fault Replace
Low battery charge Recharge
Neutral position sensor broken Replace
Clutch pump switch broken Replace
Starter motor broken Replace
Starter button broken Replace
Right-hand switch unit connection faulty Deoxidize/Repair
Starting relay switch broken Replace
Power cable connections faulty Deoxidize/Repair
Power unit failure Replace
COOLING SYSTEM
Electric fans do not work MY10->MY12: Fuse 5 blown Replace
MY13: Fuse 7 blown Replace
MY10->MY12: Fuse 5 connection faulty Deoxidize/Repair
MY13: Fuse 7 connection faulty Deoxidize/Repair
Fan relay broken Replace
Electric fan broken Deoxidize/Repair
LIGHTS/INDICATORS
Rear tail lights not working MY10->MY12: Fuse 1 blown Replace
MY13: Fuse 3 blown Replace
MY10->MY12: Fuse 1 connection faulty Deoxidize/Repair
MY13: Fuse 3 connection faulty Deoxidize/Repair
Ignition switch broken Replace
Ignition switch connection faulty Deoxidize/Repair
Device damaged Replace
High beam does not work MY10->MY12: Fuse 2 blown Replace
MY13: Fuse 4 blown Replace
MY10->MY12: Fuse 2 connection faulty Deoxidize/Repair
MY13: Fuse 4 connection faulty Deoxidize/Repair
Bulb burnt out Replace
Low beam does not work MY10->MY12: Fuse 3 blown Replace
O
MY13: Fuse 4 blown Replace
MY10->MY12: Fuse 3 connection faulty Deoxidize/Repair
MY13: Fuse 4 connection faulty Deoxidize/Repair
Bulb burnt out Replace
Bulb connections faulty Deoxidize/Repair
Ballast control unit damaged Replace
Lights switch broken Replace
Lights switch connection faulty Deoxidize/Repair
Ballast relay broken Replace
Ballast relay connection faulty Deoxidize/Repair
-2-
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Diagnostic
INSTRUMENT PANEL
Instrument panel does not work MY10->MY12: Fuse 1 blown Replace
MY13: Fuse 5 blown Replace
MY10->MY12: Fuse 1 connection faulty Deoxidize/Repair
MY13: Fuse 5 connection faulty Deoxidize/Repair
Instrument panel broken Deoxidize/Repair
Instrument panel connection faulty Deoxidize/Repair
CAN line error Instrument panel connection faulty Deoxidize/Repair
Power unit connection faulty Deoxidize/Repair
Power unit failure Replace
Speedometer does not work Speed sensor broken Replace
Speed sensor connection faulty Deoxidize/Repair
MY10->MY12: Fuse 1 blown Replace
MY13: Fuse 5 blown Replace
MY10->MY12: Fuse 1 connection faulty Deoxidize/Repair
MY13: Fuse 5 connection faulty Deoxidize/Repair
Instrument panel broken Deoxidize/Repair
Instrument panel connection faulty Deoxidize/Repair
Water temperature gauge does not work Temperature sensor broken Replace
Temperature sensor connection faulty Deoxidize/Repair
Oil warning light does not work Oil pressure sensor broken Replace
Oil pressure sensor connection faulty Deoxidize/Repair
Instrument panel broken Replace
Instrument panel connection faulty Deoxidize/Repair
Gear indicator not working Gear position sensor broken Replace
Gear position sensor connection faulty Deoxidize/Repair
O
Battery warning light does not work (MY10->MY12) Alternator connection defective Deoxidize/Repair
Regulator connection defective Deoxidize/Repair
Instrument panel broken Replace
Instrument panel connection faulty Deoxidize/Repair
ABS warning light does not work (MY13) ABS system defective Verify with TEXA diagnostic sw.
Instrument panel broken Replace
Instrument panel connection faulty Deoxidize/Repair
Side stand warning light does not work Side stand switch broken Replace
Side stand switch connection faulty Deoxidize/Repair
Instrument panel broken Replace
Instrument panel connection faulty Deoxidize/Repair
-3-
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Diagnostic
Low fuel warning light does not work Fuel level sensor broken Replace
Fuel level sensor connection faulty Deoxidize/Repair
Instrument panel broken Deoxidize/Repair
Instrument panel connection faulty Deoxidize/Repair
Indicator warning light does not work Flasher unit broken Replace
Flasher unit connection faulty Deoxidize/Repair
Instrument panel broken Replace
Instrument panel connection faulty Deoxidize/Repair
Low beam warning light does not work Instrument panel broken Replace
Instrument panel connection faulty Deoxidize/Repair
Ballast control unit damaged Replace
High beam warning light does not work Instrument panel broken Replace
Instrument panel connection faulty Deoxidize/Repair
Ballast control unit damaged Replace
IGNITION - INJECTION
(MY10->MY12: Perform verification with Weber/Marelli diagnostic software) - (MY13: Perform verification with TEXA diagnostic software)
Air pressure/temperature sensor indicates malfunction Sensor broken Replace
Sensor connection faulty Deoxidize/Repair
Engine temperature sensor indicates malfunction Engine temperature sensor broken Replace
Engine temperature sensor connection faulty Deoxidize/Repair
IGNITION SYSTEM
No sparks at the plugs MY10->MY12: Fuse 4 blown Replace
MY13: Fuse 2 blown Replace
MY10->MY12: Fuse 4 connection faulty Deoxidize/Repair
MY13: Fuse 2 connection faulty Deoxidize/Repair
Power relay broken Replace
Power relay connection faulty Deoxidize/Repair
Coils broken Replace
Injection control unit broken Replace
Safety switch broken Replace
Spark plug broken Replace
O
Engine earth connection faulty Repair
Side stand switch broken Replace
Safety control unit fault Sostituire
Engine pick-up broken Replace
Pick-up gap / phonic wheel incorrect Repair
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Diagnostic
FRAME
STEERING
Steering stiff Steering bearings damaged Replace
Steering bearings overtightened Adjust
Steering pin bent Replace
Steering damper action excessive Adjust
Steering damper joints damaged Replace
Tyre pressure low Adjust
Vehicle tends to steer or does not travel on a straight line Fork bent Replace
Frame bent Replace
Swingarm bent Replace
Steering damper joints damaged Replace
Steering bearings damaged Replace
Wheel spindle bent Replace
Swingarm bearings damaged Replace
FRONT WHEEL
Front wheel wobbles/vibrates Wheel rim bent Replace
Wheel unbalanced Balance
Tyre faulty Replace
Tyre unsuitable Replace
Wheel bearings damaged Tighten
Spindle fixing screws loose Tighten
Spindle ring nut loose Tighten
Front wheel hardly turns Wheel bearings damaged Replace
Wheel spindle bent Replace
Brake pad friction on discs excessive (see brakes) Check
Brake discs bent Replace
Wheel spindle ring nut overtightened Use prescribed torque
FRONT SUSPENSION
Front suspension soft Fork oil deteriorated Renew
Spring preload low Adjust
Hydraulic compression damping insufficient Adjust
Fork oil level low Top up
Tyre pressure low Adjust
Fork damaged Repair
Front suspension stiff Spring preload excessive Adjust
Hydraulic compression damping excessive Adjust
Swingarm oil level high Adjust
Tyre pressure high Adjust
REAR WHEEL
Rear wheel wobbles/vibrates Wheel rim bent Replace
Wheel unbalanced Balance
Tyre faulty Replace
Tyre unsuitable Replace
Wheel bearings damaged Replace
Locknut loose Tighten
Suspension screws loose Tighten
Suspension bearings damaged Replace
Rear wheel hardly turns Wheel bearings damaged Replace
O
Wheel hub circlip displaced Check
Brake pad friction on discs excessive Check
Brake disc bent Replace
Drive chain damaged Replace
REAR SUSPENSION
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Diagnostic
BRAKES
Brake lever and pedal soft (“spongy”) Air bubbles in hydraulic circuit Bleed
Leaks in hydraulic circuit Repair
Caliper seals damaged Replace
Pump seals damaged Replace
Caliper pistons do not slide freely Check
Brake fluid level low Top up
Brake discs distorted Replace
Brake lever or pedal stiff Brake lever or pedal bent Replace
Braking action insufficient Disks dirty Clean
Air bubbles in hydraulic circuit Bleed
Leaks in hydraulic circuit Repair
Caliper seals damaged Replace
Pump seals damaged Replace
Caliper pistons do not slide freely Check
Brake fluid level low Top up
Brake discs distorted Replace
Brake pads rub against brake disks Brake pad springs damaged Replace
Brake discs distorted Replace
Caliper pistons do not slide freely Check
Brake fluid level too high Adjust
Brake pads worn down Replace
EXHAUST SYSTEM
Exhaust noise excessive Exhaust pipe damaged Replace
Exhaust pipe fasteners loose Tighten
Engine performance poor Exhaust pipe damaged Replace
Exhaust pipe fasteners loose Tighten
COOLING SYSTEM
Engine temperature high Coolant level low Top up
Cooling fan faulty Replace
Expansion tank cap faulty Replace
Instrument temperature sensor faulty Replace
Thermostat locked in closed position Replace
Radiator fins bent or obstructed Repair/Clean
Radiator scaly Clean
Water pump damaged Replace
Injection/ignition system faulty Check
Fuel unsuitable Change
Engine cooling circuit faulty Check
Spark plug heat grade unsuitable Replace
Carbon formation in cylinder head/piston Clean
Engine temperature low Thermostat locked in open position Replace
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Analytical index
SECTION
Revision 3
P
-1-
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Analytical index
P
Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . .B-26 Injection time compensation (Volume) . . . . . . .D-4
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-58 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-8
Swingarm bearings . . . . . . . . . . . . . . . . . . . . .B-62 – Atmospheric air temperature/pressure . .D-8
Technical information . . . . . . . . . . . . . . . . . . . .B-3 – Throttle body position . . . . . . . . . . . . . . .D-10
Throttle body adjustment and calibration Technical specifications -
(MY10->MY12) . . . . . . . . . . . . . . . . . . . . . . . . .B-38 secondary air system (MY10->MY12) . . . . . . .D-16
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Analytical index
P
– Starter relay check . . . . . . . . . . . . . . . . . .E-41 Frame control reference measurements
– Turn indicators check . . . . . . . . . . . . . . . .E-41 (F4 S - FT - RR) . . . . . . . . . . . . . . . . . . . . . . . .G-37
– Water sensor . . . . . . . . . . . . . . . . . . . . . .E-40 Frame control reference measurements
Intermittence relay . . . . . . . . . . . . . . . . . . . . . .E-42 (F4 R - F4 MY13) . . . . . . . . . . . . . . . . . . . . . . .G-38
Lambda sensor . . . . . . . . . . . . . . . . . . . . . . . .E-42 Frame disassembly . . . . . . . . . . . . . . . . . . . . .G-33
Licence plate light . . . . . . . . . . . . . . . . . . . . . .E-46 Frame plate removal . . . . . . . . . . . . . . . . . . . .G-47
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Analytical index
P
– Rear brake disc assembly . . . . . . . . . . . .H-32
– Rear brake disc removal . . . . . . . . . . . . .H-31
– Rear brake pads substitution . . . . . . . . . .H-25
– Substitution and bleeding of the rear
brake fluid . . . . . . . . . . . . . . . . . . . . . . . .H-27
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