MV Agusta F4 1000 S Instruction manual

©2011
DieauchnurteilweiseWiedergabedieserUnterlagen ohne schriftlicheZustimmungvon SeitenderFa. MVAgustaS.p.A.ist verboten.
Teil N°8C00B4302-ZweiteAusgabe
ImMärz2011gedruckt

Engineworkshopmanual
MVAGUSTAF41000S-FT -R-RR

-2-
Statement
Thismanual, tobeusedbytheMVAgustaauthorisedworkshopshas beenrealisedwith
thepurpose ofassistingauthorisedpersonnel inmaintenance andrepairsoperationsof
themotorcycle. Theknowledgeoftechnical datahereinnoted,determines thecomplete
professional trainingofthetechnician. Withpurpose ofmakingthereadingofthismanual
immediatelycomprehensible,theparagraphshavebeenalignedwithdetailedillustrations
thathighlighttheargumentdealtwith.
Usefuladvice
Topreventanyproblemsandtoreachanexcellentfinalresult, MVAgustarecommend
skeepingtothefollowingguidelines:
-Inthecase ofaneventual repair,evaluatetheclient’simpressionswhostates thatthere
isanabnormal functioningofthemotorcycleandtoformulatetherightquestionsto
clarifythesymptomsoftheproblem.
-Clearlydiagnose thecause oftheabnormality. Thebasicfundamental theories canbe
absorbedbyreadingthismanual thatmustnecessarilybeintegratedtothepersonal
experience andtheparticipationoftrainingcourses thatareperiodicallyorganisedby
MVAgusta.
-Rationallyplantherepairtoavoidslack periods, e.g.thecollectionofspareparts, the
preparationoftoolsandequipment, etc.
-Toreachtheparttoberepairedlimitingtheworktotheessential operations. With
regardstothis, avalidhelpwouldbetoconsultthismanual withregardstothe
sequences ofremovaldemonstratedinthismanual.
Informativenote
MVAgustaS.p.A. iscommitted toapolicy of continuousimprovement of theirproducts. For
thisreason,therecouldbe slightdifferencesbetween thatwhichiswritten hereand the
motorcycleon whichrepairsand/ormaintenanceareabouttobe carried out. MVAgusta
modelsareexported tomanycountrieswheredifferentnormsinrelation tothe highwaycode
and homologation proceduresarevalid.Hoping thatyou will comprehend theseproblems,
MVAgustaS.p.A.reservesthe righttomakemodificationstoitsproductsandtechnical
documentation atanymoment and withoutpriorannouncement.
Respectanddefendtheenvironment
Everything thatwedo hasrepercussionson the entireplanet and itsresources.MVAgusta,
wanting toprotectthe interestofthe people,wouldliketomakethe clientand the technicians
ofthe technicalassistancecentresawareand toadoptmodalitiesofuseofthe motorcycle
and the disposureofitspartsinfull respectofthe normsinforceintermsofenvironmental
pollution, disposaland the recycling of waste.

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General index
GENERALDESCRIPTION................................................................. A
MAINTENANCE................................................................................. B
CYLINDERKIT.................................................................................. C
CYLINDERBLOCK........................................................................... D
LUBRICATION................................................................................... E
ELECTRICALCOMPONENTS.......................................................... F
TIGHTENINGTORQUES................................................................... G
SPECIALTOOLS.............................................................................. H
ANALYTICALINDEX......................................................................... I
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SECTION
REVISION0
A
-1-
Generaldescription
A

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Generaldescription
A
SUMMARY
HOWTO CONSULTTHISMANUAL......................................................................................Page 3
THEPURPOSE OFTHISMANUAL.......................................................................................Page 3
GLOSSARYANDSYMBOLS..................................................................................................Page 4
RIGHTHANDANDLEFTHANDSTANDARD........................................................................Page 6
SAFETY.................................................................................................................................Page 7
OBSERVATIONS....................................................................................................................Page 9
INDEX....................................................................................................................................Page 9
OPERATIVE TECHNICALSPECIFICATIONS.........................................................................Page 10

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Generaldescription
A
HOWTOCONSULTTHISMANUAL
Orderofthesubjects
Thismanualisdivided intochaptersthatdealwiththe
sub-groupsofthe motorcycle.Toquicklyfindthechapter
required,the pagesofeachchapteraremarked witha
referencemarkaligned totherelativeiteminthegeneral
index.
Display oftheoperations
Theoperationsofdisassembly,assembly,removaland
controlarepresentedwiththe helpofillustrations
(designsand photographs).The illustrationscontain
symbolsthatindicatethe procedure,specialtoolsand
otherinformation.See thesymbolslistsfortheir
significance.The proceduresaredescribed stepafter
step.
EXAMPLE
Steering pintightening
Screwinthe steeringpinflangering,withouttightening.
Thisoperation mustbedonemanually.
Check that the steeringbaseisattheend ofitstravel,
tothe right. Usingthespecialtool N.800091645,tighten
thering(1)byrotatingit10°calculatedapproximately
asone thirdofthe movementbetween the twoholesof
thering(2)ofthe steeringhead (seethefigure).
PURPOSE OFTHEMANUAL
Principally, thismanualhasbeenwritten forMVAgustadealersandqualified mechanics.It isnot possibleto
documentall theknowledge necessaryforamechanicinamanual.Thosewho utiliseit must haveabasic
knowledge ofmechanicalconceptsand the inherent proceduresinthetechniquesofrepairingmotorcycles.
Without thisknowledge, themaintenanceandrepairoperationscan renderthe motorcycleunsafeforuse.
Updates
MVAgustaS.p.A.iscommitted toapolicyofcontinuousupdatingofthe modelsproduced.The modificationsand
significantchangestothespecificationsand theprocedureswillbecommunicated totheofficialdealersand will
appearinfutureeditionsofthismanual.All information,instructionsand technicaldataincludedinthismanualare
based uponinformation on the productupdated atthe momentofgoingtoprint. MVAgustaS.p.A.reservesthe
right tocarryout changesat anymomentwithout priornoticeand withoutincurringanyobligation.

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Generaldescription
A
ATTENTION
WARNING
Thissignifiesthatthelackor
theincompleteobservance
ofthisadvicecan begravely
dangerousforyoursafety
and forthe safetyofother
persons.
Thissignifiesthatthelackof
observanceofthese
instructionscanbring therisk
ofdamagetothe motorcycle
andthe equipment.
Duringthiskindofprocedure
inflammablevapoursmightdevelop
andmetallicpartsmightbe expelled
athighvelocity.Thus,itisnecessary
to:
-workfarfromexposed flamesand
sparks;
-wearprotectiveclothing;
-wearprotectiveeye-glasses.
Incaseitshouldbenecessary,dueto
wear,tosubstituteaparticular,relative
toacylinder,westronglysuggestthat
youcheckand ifnecessary,substitute
the sameparticularinall ofthe
cylindersformoresatisfying results.In
particular,werecommend thatatthe
sametimeyou substitute:
-pistonswithrelativeelasticbands
and piston pins;
-valveswithrelativesprings, semi-
cones,disks and grazings;
-Valveguideswithrelativevalves,
springs, semi-conesand grazings;
-bed bearing;
-whateverelseundergoesuniform
wear, aside fromthe position ofthe
relativecylinder.
Inordertoallowthe motortofunction
underthe bestconditions,itis
necessarythatall ofthecouplingsare
withintheaccepted tolerances
established.Atightcoupling,isinfact,
causeforseizureassoon asthe
organsinmotionbegintoheat, while
aloosecouplingiscauseforvibrations
whichaccelerateswearon the
particularsinmotion.
GLOSSARYAND SYMBOLS

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Generaldescription
A
Supplieskeyinformation forthe best
fulfilment of the operation.
Utiliseaspecifictoolorequipmentfor
thecorrect carryingoutofthe operation
described.
Tighten tothe specified torque.
Toleranceorlimitof use.
Utilisethetester.
Usethe recommended oil.
Usethe recommendedgrease.
Usethe recommended brakefluid.
Usethe recommended suspension
fluid.
Usethe recommendedcoolant.
Usethe recommended thread-locking
fluid.
Usethe recommendedsealant.
Usethe recommended adhesive.
Carryoutaccuratecleaning.
Usenewcomponents.
Substitutethe component.
Donot leavelitterabout.
NOTE Allofthecountersignsindictingright, left,
superior,inferior, front and back, refertothe
motor-bikeinthe normaldirection ofmarch.
Themotorsupportsnumberingofthe cylinders
andoftheattached components,increases
movingfromleft towardsrightinregardstothe
direction ofmarch.
Thissymbolindicates"the procedures
tobecarried out withanemptycooling
circuit".

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Generaldescription
ARIGHTHANDANDLEFTHAND STANDARD
Toclarifytherighthandand left hand standardthatisused inthismanual, herewithbelowisadiagramof the
motorcycleandthe engine against whichareindicatedthe right and left sides.
Cylinder1
Cylinder2
Cylinder3
Cylinder4
RhSide
RhSide
Lh Side
Lh Side

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Generaldescription
A
SAFETY
The informationcontainedinthis paragraph is fundamentalso thatthe operations
carriedout on the motorcycle can be conducted with minimumriskto the mechanic.
Carbon Monoxide
•Exhaust gasescontaincarbon monoxide (CO)that ispoisonous. Carbon monoxide can causethe loss of
consciousness and death.
•Ifit isnecessarytoswitchon the engine, check that the environment iswell ventilated. Neverswitchon the
engine inan enclosed environment.
•Switchingon the engine can onlybecarried out inan enclosed environment when therearethe appropriate
devicesforthe evacuation ofexhaust gases.
Petrol
•Petrolisextremelyinflammableand undercertainconditionscan beexplosive.
•Keepsourcesofheat, sparks and flamesawayfromthe workarea.
•Alwaysworkinawell-ventilated area.
•Neverusepetrolasacleaningsolvent. Generally,avoidhandlingit unless it isabsolutelynecessary.
•Donot usepetrolforcleaningcomponentsbyusingcompressed air.
•Keeppetrolout ofreachofchildren.
Engineoil
•Engine oil can causeskinillnessesifinconstant and longcontact withthe skin.
•Ifthe skincomesintocontactwithengine oil, washthe partsaffected assoon aspossiblewithsoapand water.
•Ifengine oil comesintocontact withthe eyes, rinseabundantlywithwaterand seekmedicalattention.
•Ifengine oil isswallowed, do not provocatevomitingtoavoidthe aspiration ofthe product intothe lungs.
Transport the injured person immediatelytohospital.
•Used oil containsdangeroussubstancesand poisonousforthe environment. Tosubstituteoil,it isnecessary
tobeequipped todealwiththe collection of used oil inrespect ofthe normsinforce.
•Donot disposeofused oil inthe environment.
•Keepused oil out ofthe reachofchildren.
Enginecoolant
•Undercertainsituations, the ethylene glycolcontained inthe engine coolant isinflammableand itsflameis
invisible. Ethylene glycolwouldcauseseriousburnsifignited becauseit isinvisible.
•Avoidbringingthe engine coolant intocontactwithhot parts. Suchpartscouldbesufficientlyhottoignitethe
coolant.
•The engine coolant (ethylene glycol)can causeirritation ofthe skinand ispoisonousifswallowed.
•Ifthe engine coolant comesintocontact withthe skin, immediatelyremoveanycontaminated clothingand
washwithsoapand water. Ifit comesintocontactwiththe eyes, abundantlyrinsewithclean waterand
immediatelyconsult adoctor. Ifswallowed, do not provocatevomitingtoavoidthe aspiration ofthe product
intothe lungs.Administerclean waterand transport the injured person immediatelytohospitaland showthe
product toadoctor.
•Ifexposed tohighconcentrationsofvapour, transport the injured person toanon-poisonousatmosphereand if
necessarycall adoctor.
•Donot removethe radiatorcapwhen the engine isstill hot. Beingunderpressure, the engine coolant can be
violentlyejected and thereforeprovocateburns.
•The engine coolant containsdangerousand poisonoussubstancesand isthereforedangerousforthe
environment. Tosubstituteused engine coolant, it isnecessarytobeequipped todealwiththe collection of
used oil/ofused engine coolant inrespect ofthe normsinforce.
•Donot disposeofengine coolant inthe environment.
•Keepengine coolant out ofreachofchildren.
ATTENTION

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Generaldescription
ABrake fluid
•Brakefluidisextremelycorrosive.
•Avoidanycontactswiththe eyes, skinand the mucousmembrane.
•Ifbrakeliquidcomesintocontactwiththe skin,removeall contaminated clothingand washimmediatelywith
soapand water.
•Ifbrakefluidcomesintocontact withthe eyes,abundantlyrinsewithwaterand call adoctor.
•Ifswallowed,do notprovocatevomitingtoavoidaspiration ofthe productintothe lungs.Immediatelycall a
doctor.
•Takethe injured person immediatelytohospital, if he hasbreathed brakefluidintothe lungs.
•Inthe caseofexposuretohighconcentrationsofvapour,movethe injured persontoanon-poisonous
atmosphereand ifnecessarycall adoctor.
•Inthe caseofaccidentalcontact, rinseabundantlywithwaterand call adoctor.
•Keepbrakefluidout ofreachofchildren.
Thread-locking fluid
•Asitisnotclassified asdangerous,the prolonged contactwiththe skin,particularlywithregardstoabrasionscan
provocatesensitiveness and dermatitis.Inthe caseofcontactwiththe skin,rinseabundantlywithrunningwater.
•Movethe injured person intothe open airand call adoctorifthe injured person feelsill afterhavingbreathed in
the product.
•Inthe caseofcontactwiththe eyes, rinseabundantlywithwaterforat least 15 minutes.
•Ifthe thread-lockingfluidhasbeen swallowed,drinkan abundantquantityofwaterormilk.Donotprovocate
vomitingtoavoidthe aspiration ofthe product intothe lungs. Immediatelycall adoctor.
•Keepout ofreachofchildren.
Nitrogen-rearshockabsorber
•The rearshock absorbercontainsnitrogen underpressure.
•Beforedisposingofused shock absorbers, dischargethe nitrogen viathe depressurisingvalve.
•Utiliseonlynitrogen topressurisethe shock absorber.The useofunstablegasescan causeexplosionsthatcould
causeburns.
•Donotplacethe shock absorberneartoflamesorsourcesofheatasthiscouldcauseexplosionswithconsequent
burns.
•Keepout ofreachofchildren.
Battery
•The batteryproducesexplosivegases.Keepitawayfromsparks,flamesorcigarettes.Duringrecharging,
adequatelyventilatethe environment.
•The batterycontainsasolution ofsulphuricacid(electrolyte).
•Sulphuricacidiscorrosiveand itdestroysmanymaterialsand clothing.Oncontactwithsmall quantitiesofwater
itgeneratesaviolentreaction thatmanifestsitselfbycreatinglargequantityofheatand spurtsofhotacid.
Sulphuricacidattacks manymetalstherebyliberatinghydrogen:an inflammablegasthatformsan explosive
mixturewhen mixed withair.
•Contactwithsulphuricacidcancauseburns.Inthe caseofcontact, removeimmediatelyallcontaminated clothing
and washthe skinwithabundant quantitiesofwater. Takethe injured person tohospitalifnecessary.
•Inthe caseofcontact withthe eyes, rinseimmediatelywithabundant water. Call adoctorand continue withthe
treatment until the doctorarrives.
•Ifthe electrolyteisswallowed,rinsethe mouthwithwaterwithoutswallowing.Takethe injured person immediately
tohospitaland explaintothe doctortherewhat the injured person hasswallowed.
•Thebatterycontainsdangeroussubstancesthatarepoisonousforthe environment.It isnecessarytobeequipped
todisposeofthisproduct inrespect ofthe normsinforce.
•Donot disposeofused batteriesinthe environment.
•Keepout ofreachofchildren.
Hot parts
•The engine and the exhaustsystembecomeveryhotand maintainthistemperatureforsometimeafterthe
engine hasbeenswitched off.Waitforthesepartstocooldownbeforehandlingthemorworkingonthe motorcycle
neartothem.Useprotectivegloves.

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Generaldescription
A
WARNING
The information contained inthisparagraphisimportant
sothatthe operationscarried outonthe motorcyclecan
beconducted withoutdamagingthe motorcycle.
•Thoroughlyclean the motorcyclebefore
disassemblingit.
•Duringdisassembly, clean all partsand placethem
incontainersrespectingexactlythe orderof
disassembly.
•Alwaysusethe specialutensilswherenecessary
andeachtimewhereprescribed.
•Alwaysuseadhesives,sealantsand lubricantswhere
prescribed. Respect the instructionsabout their
technicalcharacteristics.
•Alwayssubstitutepartssuchasgaskets, O-rings,
securitywasherswithnewparts.
•Slackeningortighteningnutsorscrews,alwaysstart
withthoseofagreaterdimension orfromthe centre.
Alwaysrespect the torque valuesindicated.
•UtiliseonlyMVAgustaspareparts.
INDEX
GENERALINDEX SUMMARYOFEACHCHAPTER

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Generaldescription
AOPERATIVETECHNICALSPECIFICATIONS
MOTORCYCLEIDENTIFICATION
Theregistrationnumberofthe motorcycleisstamped ontherightside ofthesteeringhead.The engine
registration numberisstamped on theupperengine casing,nearthe forks.
Belowisan exampleofthe designation oftheframeregistrationnumber:
Manufactureridentification
Vehiclemodel
Progressiveframenumber
2)Engineregistration number
1)Frame
registration
number
3)Homologation data
ZCG F6 10 AAYV000001

SECTION
REVISION1
B
-1-
Maintenance
B

-2-
Maintenance
BSUMMARY
PLANNEDMAINTENANCESCHEDULE................................................................................Page 3
THROTTLEBODYADJUSTMENTANDTUNING..................................................................Page 11

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Maintenance
B
PLANNEDMAINTENANCESCHEDULE
The following diagramshowsthe recommended planned maintenanceintervals. Periodicmaintenanceisessen-tial
tokeep the vehicleinperfect running orderand toensureoptimumcost efficiency.
Useshortermaintenanceintervalsifthevehicleisused in particularlyharshconditions.
Letushelp protecttheenvironment
Everything wedo affectstheentireplanetand itsresources.Toprotect thecommon interest, MVAgustaurges
itscustomers andserviceoperatorstousethevehiclesand disposeoftheircomponentsin com-pliancewith
applicableregulationson environmentalpollution control, wastedisposaland recycling.
Programmedmaintenanceschedule
01000 6000 12000 18000 24000 30000 36000
Km(ml)covered (600) (3800) (7500) (11200) (14900) (18600) (22400)
Service pre- A B C D E F G
delivery
Description Operation . . . . . . .
Engineoil Substitution Atleast onceayear
Substitution . . . . . . .
Engineoilfilter (utilizeonlyMVAgusta
originaloil filter) Ateverysubstitutionofengineoil
Check level/Top up . . . . . . . .
Engine coolant Substitution every2years
Cooling Check forleakages . . . . . . . .
Electricfan Check functioning . . . . . . . .
Valves Check / adjustment ...
Check . .
Timingchain Substitution .
Check /Substitution . .
Timingmovablepad .
Substitution Atleast everysubstitutionof thetimingchain
Timing chaintensioner Check /Substitution ...
Check /Substitution . . .
Sparkplugs Substitution ...
Fuelfilter Check /Substitution ...
Throttlebody Check and adjustment . . . . . . .
Airfilter Check /Substitution . . . . . .
Checklevel . . . . . . .
Brakeand clutchfluid .
Substitution every2years
CheckFunctioningandCircuit . . . . . . . .
Brake/Clutch Cleaningof contactleverand . . . . . . . .
pump piston area
Brakepads(frontandrear) Check /Substitution . . . . . . .
Checkfordefectsandleakages . . .
Fueltubes Substitution every3years
Check functioning . . . . . . . .
Acceleratorcontrol Verify/ adjustplay . . . . . . . .
Startercontrol Check functioning . . . . . . . .
Transmission/ flexiblecontrols Check / Adjustment . . . . . . . .
Check / Adjustment . . . . . . . .
Transmission chain Lubricate . . . .
Substitution ...
WARNING

-4-
Maintenance
B
Programmedmaintenanceschedule
01000 6000 12000 18000 24000 30000 36000
Km(ml)covered (600) (3800) (7500) (11200) (14900) (18600) (22400)
Service pre- A B C D E F G
delivery
Check . . . .
Pinionwheel/ Stopwasher . . .
Substitution Atleast at eachsubstitutionofthe transmissionchain
Check . . . .
Crownwheel . . .
Substitution Atleast at eachsubstitutionofthe transmissionchain
Crownwheeltension regulator Check /Substitution . . .
Steeringheadflange ring Check / Adjustment . . . .
Check / Adjustment . . . .
Steeringbearings Lubrication .
Check forpressure . . . . . . . .
Tyres Checkforwear . . . . . . .
. . . . . . . .
Wheelrims Visualcheck Everytyresubstitution
.....
Frontwheelbearings Check Everytyresubstitution
Substitution .
Side stand Check functioning . . . . . . . .
Check functioning . . . . . . . .
Side standswitch Substitution . . . . . . . .
Check /Lubricate . .
Rearwheelhub rollerbearingsandguide
Substitution/ Lubricate .
rollerbearingsandguide
Rearforkbearings Check/Lubrication .
Chainguideframeplate Check / Adjustment . . . . . . .
Rearshock absorber Check / Adjustment . . . .
Front forkoil Substitution .
Batteryconnections Check andclean . . . . . . .
Electricalsystem Check functioning . . . . . . . .
instruments Check functioning . . . . . . . .
Lights/Visualsignals Check functioning . . . . . . . .
bulbreplacement
Horn Check functioning . . . . . . . .
Check functioning . . . . . . . .
Frontheadlight bulbreplacement
Adjust ateveryvariationof ridingset-upofthemotorcycles
Ignition switch Check functioning . . . . . . . .
Locks Check functioning . . . . . . . .
Torquesettings-nuts andbolt Check /Tightness . . . . . . . .
Tubeband fasteners Check /Tightness . . . . . . . .
Generallubrication . . . . . . . .
Generalcheck . . . . . . . .